My friends ion is leaking down the barrel. tried everything to try to fix it. hoses look good, pressure is at 140, we even turned it way down to make sure the gauge wasn't off and we had it over pressurized. we checked all bolt orings, oiled the gun, ect.
I don't know whats wrong, but in the manual I believe it has a section for leaking's and such like down the barrel maybe you missed something.
If you can't figure out the problem, I would send it into Smart Parts to get check/fixed they do a pretty good job with repairs. My Ion was leaking near the regulator they fixed it really well.
obviously there must have been damage to some bolt o ring that i didn't see. unfortunately, its too late for my friend, who took it to the proshop so they could charge him to fix an easy problem.