Are you brake-cleaning the mechanism in the drums or the lever/ratchet assembly? I've heard hosing down the lever/ratchet assembly helps with the "popping" that I sometimes get.

 

In the ratchet assembly under the lever. I don't think it will help the popping, once that starts the ratchet is toast and the cable snapping is coming next. It frees the ratchet up to work a little better though. Either way, it's only a short term band-aid from what I can tell.

You can adjust the spur wheels in the rotor assembly until you're blue in the face....that's not the problem, the problem is the crappy ratchet assembly under the lever sticking and failing.

 

When the lever's spring clutch begins to slip, this will often restore normal operation.
It's accessible through the brush seal.
If that doesn't prevent it from slipping, you need a new lever assembly. (About $50)

 

Thanks, guys. Cheers!

 

I got a new lever and took a break spoon to the rear end... It works great now