I'm using a direct-drive BLDC motor and was a trouble with motor and Kelly controller overheating in the past. Problem was in high RPM motor that never can reach its optimal RPM with high torque load from big prop without reduction. Problem with overheating for both motor and controller was solver by replacing electric motor to low-RPM one, with much better torque value at low RPM. My first motor was designed to 4000 RPM, but worked at 800 RPMmax because of it's lack of torque. Second motor have max RPM 1000 and at all useful RPM range it work a max temperature 80 celsus even after 10 hours of hard work. Controller temperature max is 60 celsus.
Considering your speed 3.5 knots @ 2.5 kW and your boat displacement I can suggest your drive work at low efficiency because of motor optimal RPM did not match your real RPM.
You have two ways to solve it: change electric motor to low RPM with higher torque or add a reduction.
Good luck.
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