Sounds like your Barley Crusher is in need of a manufacturer tune up. Let me save you some time and cut and paste what he initially sent me when I emailed him about a similar problem:
[font="'courier new', courier, monospace;"]A couple things I would suggest to try is to take a wire brush to the rollers.This will remove any residue that may have built up over past batches.You can also try to take the mill apart and give it a good cleaning. ( no water) try wiping the end of the rollers and the side plates off and reassembling the mill. sometime dust and residue will build up between the rollers and the side plate that will make the idle roller stick. If you do take the mill apart to clean it, one other thing you can do is spin the idle roller 180 degrees, so the side that's on the right is now on the left.If the knurl on the roller is starting to get dull they tend to dull more on one side than the other. So spinning the roller around will give that roller a somewhat fresh knurl.[/font]
After doing what he instructed to no avail, he told me to take off the base and the hopper and send him the mill at this address:
[font="'courier new', courier, monospace;"]B C Products Enterprises Inc[/font][font="'courier new', courier, monospace;"]430 Capac Rd[/font][font="'courier new', courier, monospace;"]Berlin Mi[/font][font="'courier new', courier, monospace;"]48002[/font]
then what happened?