Came home to find the bypass handle loose to the point where it would almost fall down on its own. The jam nut on the ubolt worked its way loose, probably wasn't overly tight the last time I adjusted it coupled with some serious hot and cold expansion and contraction from these last two weeks. When I loaded it I thought it was just a bit looser than normal. Fortunately, I was able to fix it while there was still hot coals in the stove. No time for a dollar bill test on the gasket, a visual was good enough for now. This is a good part of the season to make sure your gaskets, bypass and loading door are in top shape!
I had the handle drop down once but think it was just because I was a bit lax in putting it up. Never happened since. But that is a good tip.
Slight derail- My KS has always been tight. I've always wondered if it was too tight and causing excessive wear, but assumed it was adjusted correctly when it was refurbished. Hard to describe how tight bypass levers are but my my 9 y/o probably couldn't do it without some coaxing, even on a cold stove. I do it with one hand no problem but it always has a loud screech.?
It should have a semi firm engagement, I usually set mine with a dollar bill between the gasket trying to get the tension just right. It will click in with just a touch of effort.
Sounds pretty darn tight...I would back it off a hair. It's not like it has to seal against the full pull of the draft, like a door gasket, it just has to divert the flow...
Hope it doesn't happen to me, it would be a major pain getting at it with my install. Probably have to take the top off.