TBH, now that I know what circumstance causes the sticking (thanks for the analysis!) , I've modified my behaviour so that it doesn't happen any more. It's fairly intuitive fortunately because it involves plunging by applying pressure with the same hand that I release the plunge lock with.
Agree with you that it shouldn't happen for this level of tool (and whatever the rest of their products are like, I still reckon that DW make decent routers).
Will contact tech dept and see what they say....
cheers Richard
-- Richard Sampson
email me at richard at olifant d-ot co do-t uk