i bet the shiming is off. if the sector gear is to high in the box it will contact the tappet and it will be stiff. if thats not it then check the fit between the nozel and head, actualy check that first.if you are still haveing probs give me a call and ill come take a look at it. at least if your in phx, otherwise we will have to meet up somewhere. ive been playing with the p90 gearboxes for 9yrs or so. the last thing it could be is the tappet being to wide. to check that you just pop out the gears leave the spring in (tappet, not piston), put the box back together with the motor, push it back and forth and see if there is any binding. i dont think there will though.
you can reach me at: 602-446-2280
hope this helps.