Hope pro 2 freewheel sticks

When I turn it manually, the freewheel on my pro 2 rear appears to turn smoothly. While riding, however, it sticks, causing all sorts of trouble due to the slack in the chain. The hub did not stick one bit even when brand new, and is surely bedded in by now.
I have cleaned and regreased the hub. As far as I can tell, there is no play or roughness in the bearings. Is there something about the hub that I'm not spotting here? Any advice will be greatly appreciated.
I have cleaned and regreased the hub. As far as I can tell, there is no play or roughness in the bearings. Is there something about the hub that I'm not spotting here? Any advice will be greatly appreciated.
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Parktools :?:SheldonBrown
Carbon 456
456 lefty
Pompino
White Inbred
The seal will bind between the freehub and hub body if not seated correctly, and usually cause the problems you describe above.
Parktools :?:SheldonBrown
Compared the two wheels without the freewheel assembly. Could not spot a major difference in smoothness of the axle's turn. As a last resort changed the bearings in the hub body anyway and that seems to have fixed the problem.
Opening the seals in the old bearings revealed whitish goo indicating lubricant contaminated by water. Obviously the bearings were not in perfect condition even though there wasn't enough play or drag for me to notice. What I can't figure is how these bearings could cause the problems described before. Not that it matters a lot now, but it'd be interesting if someone could explain this.
OK so how could the bearings effect the situation? they may not have if may just be that you managed to fit the seal better this time
Parktools :?:SheldonBrown
Since I haven't opened the bearings until now, I'm not 100% sure about the grease. Based on previous experience I'd say this had been in touch with water.
My guess is you've probably put too much grease in there and it's got nowhere to go at high speed save for into where the pawl shouls sit so they/it can't retract.
You only need a really thin smear of grease on the pawls.
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