First, I think your gun needs to go back to Kahr. Your problems sound like the ones I first had (except my follower didn’t break). Before I sent it back to Kahr I rarely got through a magazine without a malfunction of some sort; I had lost all confidence in it. My six-rounder was the more problematic magazine, too, and the overwhelming majority of malfunctions with both magazines were on the last round.
Mine was only gone seven days, round trip, so it was pretty painless. Once I got through to them, at any rate, which is easier said than done. FWIW, they replaced the recoil spring & guide and mag catch pin, polished the feed ramp, barrel hood, extractor, extractor bore and slide stop. And I’ve been happier with it than a dead pig lying in the sun ever since.
From everything I have heard, the best way to get through to them is by FAX. That’s what worked for me. The FAX number I have for them is 508.795.7046. They seem to completely ignore E-mail, which I find absolutely asinine. Frank Harris’ (VP) phone number was 845.735.4500x205. A lot of people report having better success going through Heather, who then was at 845.735.4500x309. I’d start with the FAX, give them three business days to respond, then hammer ‘em on the phones and E-mail.
I suspected overheating contributed to the problems before I sent mine back (the ‘sizzling’ sound when I inadvertently touched the slide was a clue). When Kahr returned it, I reasoned that the first task was to learn to trust it enough to use it for CCW. The first range session, I was just rippin’ ‘em as fast as I could pull the trigger. And I continued to have occasional malfunctions, but only near the end of a box of shells. In other words, only after I’d already put 30-40 rounds through it that range session. The good news is that that 100 rapid-fire rounds got me karmically-attuned to that trigger and now I love the hell out of it. Rapid fire, short barrel and all, it patterns better for me than my (full-sized) Glock 20 (whose trigger I merely tolerate).
To remove the heat factor from the equation, after that first session I fired only 10 rounds per session but went through 15 range sessions (one morning, one afternoon) until it had run through another 150 rounds without a hiccup. It did not get cleaned until the 250 were complete. I’ve stopped keeping count but I keep running a couple of magazines through it each time I go to the range. All this has convinced me that excess heat was a contributing factor.
That is a tiny gun shooting a purt’ near powerful cartridge and all the heat has to go somewhere. Combine that fact with a polymer frame (which resists heat transfer) and I think you have a sure-fire recipe for an overheating weapon. All those BTUs basically got only two places to go: out the barrel or into the slide.
But heat probably is not the only source of your problems. I spoke with Frank Harris at Kahr and he admitted they have a QC problem with unpredictable shrinkage with the polymer frames. I suspect that’s your greater problem. He also told me it tended to be more temperamental bout heavy bullets. In one other pistol-related news group I belong to, the consensus is that the PM40 is WAY more affected by this than the PM9 is. But once it’s sorted, IMHO, it’s worth the trouble.
Bottom line, I consider it a great CCW piece but as a plinker, …well, that’s what .22 LRs are for, aint’ it?