The gun could have been defective from the beginning and just took a while to break down, or you could be overcleaning it. When you say "cleaned after every outing," do you mean sprayed down with lubricant in every crevice? Spraying aerosol lubricants like WD-40 into every hole is a sure way to build crud on moving parts. The lube attracts dust, which combines with the lube to foul things up. In either case, I can't tell for sure. Your two solutions are to get serious about contacting Franchi with a phone call or letter (especially if the gun was purchased new) or contacting a full-time gunsmith who knows shotguns. I can recommend Heckman Specialties, www.heckspec.com.