Quoted from ChipScott:
With the problem occurring only with the hyperspace multi-ball, makes me think there has to be some switch above the fork as it enters into the ramp that might not be getting reliably triggered, thus it seems like that would probably be the switch (or opto) that needs to be adjusted to acknowledge a ball entering the ramp (or passing by).
That said, the fact that you are able to get a second ball in that hyperspace ramp during that multi-ball implies that whatever that switch is, it does register (at least once) because a second ball comes out into play. I wonder if there are any other registering mechanisms present on that hyperspace loop or if all of the switches are hidden underneath the death Star (which is probably the case) to register both entering and passing balls. In your case, I wonder if as the balls are going around (during hyperspace mb) they are potentially going too fast to register a switch on that loop that maybe sitting a bit low, or an opto that's positioned a bit too low (both of which probably have some degree of adjustment that could be made)?
So just now I took an extra ball and run a game with the glass off. When HS mb started, I took the 2nd ball on the pf, plus the extra ball, and loaded them into the loop (not at the fork jump, just tossing it inside the wireform). Then the game would launch another ball. Then I tried again without an extra ball, and only loaded the 2nd ball, and the game sent me a third ball. Hooray! Started another game and it still worked. Hopefully it works in a real game now!
I did consider the optos but in all my testing in test mode I would see all 4 optos run every time. So we'll see how this goes. If the problem continues I'll have to ping Dwight because he obviously knows exactly how it keeps track of balls in the loop. It must time the one ball when it starts, as a baseline, then if sees an opto trigger too early, it know there's 2, etc. So all it has to do is say, in this given amount of time, how many times did one of the optos register? The question is, does HS hurry-up allow any of the 4 optos to count as a shot, whereas in HS mb, only of the 4 is used for counting, and if that opto is flaky, you're hosed.