Okay, I took another look at it.  With the case removed, I powered up the
servo and narrowed down the problem to the sole plastic first gear (the one
that engages the motor pinion) and the gears it contacts with.  I took
apart a spare 341 servo I had lying around and found that the plastic gear
in that one was the same as the plastic one in the 368.  A closer look at
the 368 gear revealed that, while there were no missing teeth, the teeth on
the inner cogs seemed to have a worn or slightly ragged look.  I popped the
newer gear into the 368 and it seems to have fixed all the problems.  The
servo sounds good, holds under load, and I can no longer spin the output
shaft with my fingers.

I can only assume that the rigors of over a year of DS flying had slowly
eroded the single plastic gear.  The twig that struck the flap the other
day was probably just the last straw.  I guess it would probably be a good
time to check the other servos in that wing as well. :)

At 04:14 PM 12/15/03 -0600, John Diniz wrote:
>Brett,
>
>Sounds like the pot is bad (DS machine huh?):^). Call our service department
>and sent it in for repair or replacement. Horizon service ph# is
>217-355-9511. Gotta love the 3-year warranty. 
>
>Regards,
>John Diniz
>HHD R&D Manager

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Brett's Slope and Power Home Page: http://home.earthlink.net/~jaffee
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