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I don't know how I missed seeing this thread before...
I am dubious that this problem is any of the stuff y'all have said. At least, on my Halcyon Halos...
The reason I am dubious is that, first, mine do not have very many hours on them.
And second, because after servicing them, the problem seems to go away and then gradually come back after not too long. If it was a ridge or something in the air barrel, it seems like the problem would not go away and then gradually come back.
And third, it's obviously not mismatched parts, as my Halos did it from not too long after new and only have original OEM parts.
Mine are at my shop right now for someone more knowledgeable than me to work on them. I think Halcyon is also supposed to have sent some new parts, too, but I don't know details on that.
Lastly, I have 2 Halos on my single tank reg set. They both do it. The one I use as my primary does it worse.
The Halo/G250V use a sleeve over barrel to prevent lever from catching and to smooth out action. If it was a G250 lever catching could be issue, I have come across it before but now I think about it it's unlikely to be lever on a halo.
Lube on poppet O rings wearing off