faulty hop-up nub, from an upgrade hop-up unit.
I am reverting back to stock... my experience with upgrade hop units is that they mostly suck.
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Basically, you want the first tooth of your sector gear to strike the pickup tooth on your piston flat-face-on-flat-face -- i.e. maximum contact surface area. The best way to accomplish this is to get a sorbo pad (airsoftparts has em) and stick to the rear of your cylinder head. This will move the strike position of your piston back enough that the two teeth can achieve this angle of contact. You'll then need to test the engagement out by hand and check if you need to remove any teeth from your piston to allow the sector to hit the pickup tooth before hitting anything else.
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interesting, thanks!