Speaking only for j-d, I spent a lot of time pondering this generator problem. The symptoms seemed inconsistent. The unit was new. You had used and exercised it. Warranty was an issue. Even more so, BTW with TEXAS' comment above. A lot of what you said pointed to not wanting any evidence of tinkering. Since I can only speak for myself, I don't know if others were in the same quandry.
This is your new rig and I know you want it all just right. Many things have what they call a "bathtub shaped trouble curve" where there's a spike of initial problems. This corresponds to the steep faucet end of the tub. Then a long period of very limited problems, the sloping bottom of the tub. Finally, a steep upturn in problems, probably time to overhaul or replace.
Hopefully you'll settle the generator and it'll be good for years.
Again, speaking for myself, I'm always disappointed when I read about a problem and can't offer even a sliver of a solution.
