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If I understand your problem correctly the headsail was partially furled and you then encountered a building breeze and made a couple of tacks, then when you pulled hard on the furling line after letting the sheets loose, the sail would not roll up any further. If that is the problem you encountered you may want to experiment some on a less windy day troubleshooting the following theory.
The idea behind easy furling is a relatively tight forestay and a relatively loose halyard. Think about a bakers rolling pin. It wouldn't roll too easily if it wasn't perfectly round. Also think bout the handles. If the handles were pressed too tightly against the roller, it wouldn't roll easily. The furling system works the same way but on a much larger scale. A sagging forestay ruins the straight line the sail needs to travel around when it rolls up. A tight halyard increases the loads on the top and bottom bearings..once again making it harder to roll up. When a sail is partially rolled up, and the wind builds, the same things are happening as the sail that is wrapped around the furler tightens up and acts like a tightened halyard. The forestay sags due to the increase in pressure from the breeze and the whole thing is hard to work.
What you might consider is to go out on a 10 knot day and unfurl the headsail, then loosen the halyard until you see some small wrinkles coming back from the luff. Then tighten up the backstay till the forestay is straight as you will have it when sailing in a bigger breeze, then slack off the halyard some more till the wrinkles come back. Try rolling up the headsail at this point a few turns, then unroll it some and roll it back up. When you are happy with the performance, mark the halyard and backstay settings with a sharpie marker so you can reset them easily. Slacking off on the halyard in a building breeze is the exact opposite of what you want to do to maintain sail trim, but once you roll it up partially, you will be relieving some of the pressure on the furled sail.
The interaction between the headstay tension and the halyard tension is sort of a black art and you may have to experiment some to get it just right.
Hope this helps some,