OK, after battering Amos and Dark Angel over TS/MSN for a good 2.5 hours we have not come to a solid solution other then possibly bad shimming, which I am sure is fine...
So here is the issue.
Up until today, the box was working fine, I opened it up to put in a new lower powered spring. Put the box back together and went to test fire and that when the fun began.
Basically what is happening is in semi mode, the gear is cycling a bit past the point where the cut off leaver engages and end up holding the nozzle back, the way the gun then continues to cycle stops the bbs from firing consistently, and has killed the air seal - otherwise - useless in semi, the ONLY MODE I USE >:(.
After numerous tests, Its been determined that the cut off leaver IS engaging and separating the contacts. The sector gear cannot be moved until the trigger is released and pulled again. but as soon as I assemble everything again it fucks up.
The pic shows where it is stopping. The nozzle and tappet plate are fully to the rear, it cannot be pushed in or be pulled out at all.
Hopefully somebody can help me out on this :S