It is a design flaw. Hope they fixed it in the 705
I think they may have.. The 705 feels a lot more solid, and the biggest improvement for me is the *gasp* screws (torx) holding the thing together. I guess only time will tell.
I would second (3rd, etc) the comment not to take it apart, and to just return it.. I took my 305 apart to fix the problem, which i was successful at.. until i got caught in a sudden deluge..and apparently my repair wasn't as waterproof as i would have liked. Oh well.. excuse to but new 705. (Lovin' it btw)