I had that.. I have resolved it now. Mine started off as a 450 Pro flybar went to a FBL on V2 head and now into a DFC setup. I changed the main beaing blocks to the new design that came out with the DFC ones, and I had that same bind.
ok .. this is what I will have you check .. TOny can add to this when he comes around at night : (REMOVE THE TAIL BOOM BLOCK JUST TO BE SURE ITS NOT THE MESH BETWEEN THE TAIL BOX AND THE AUTO GEAR)
1) take off the main gear and pull the main gear apart from the anti rotation gear. The anti rotation gear has a sleeve in it which the screw goes through . Take that sleeve out (its not glued in, its just pressed in .. ) .. and check for excess plastic under there on the small anti rotation gear. if there is take a little sand paper or file and make it smooth .. clean it off, and reseat that long sleeve in and make sure its in ALL the way .
2) The One Way Bearing (reffered to as OWB) sitting on the main gear : is that OWB seated properly.. Are all the screws tight ? (NOT supoerhuman tight.. just tight enough .. ) and did you tighten them in a star pattern (alternates) like you would on a car wheel ? If not, take that out by just unscrewing those phillips head screws and re seat that, tightening in a star / alternates pattern ..
3) Check that the main shaft bearing blocks are on there just right and you can slide your main shaft through both simultaneously in and out, without any bind...
4) Then ... you must have a little washer / collar (bronze or silver in color) that sits on top of that OWB when you insert that auto rotation gear through before pushing the main shaft through , take that washer off (TEMPORARILY) and seat the main gear with auto rotation gear back on the frame and sit the main shaft though it, and put the bolt in.. see if its too tight still ..You should have some minor play up and down and the Auto rotation gear should be free as silk... .
If thats the case, then try again, with the collar / washer in it this time and see if the bind returns..
if it does ... Then now use a file or sand paper or something like that to sand off some material off that little washer and check and recheck .. you'll hit just the right thickness very soon.
Make sure to clean it thoroughly after sanding and oil the bearings
