Cool, thanks for the ideas, guys. I'll take it apart and give it a good once over and see if that helps. The quality of the grill is amazing, and I sure don't want to scrap it because of a bad burner.
Funny story:
When my grill was about 2 years old, I moved to a new house with a walk-out basement. I put the grill up on the main level deck right outside the kitchen, but hadn't gotten it hooked up to the cylinder yet (the moving company won't move a cylinder).
The first night we were in the house, a wicked storm blew up. As a new homeowner, I was paranoid about what might be happening to my investment. Then I heard the most horrible crash ever. I ran downstairs and looked for the source.
To my horror, the grill was gone off my deck. The wind had rolled it down the stairs. I scrambled in the pouring rain and gathered up the grill, grates, flavorizer bars and tabletops and pulled them into the basement. I was absolutely soaked and filthy.
The next day I surveyed the damage. I had a couple cracked work surfaces, the tank scale was destroyed, the ignition switch was toast, and the deck steps had a couple pretty good gashes. From what I could deduce, the grill actually did a cartwheel going down the stairs (a full story tall, no less).
At that point, I had only one choice: I had to fire it up. I put together all the parts that had flown out and rolled it clear out to the edge of the property in the back yard. I sure didn't want to have the thing blow up close to the house. I turned on the gas, tossed in a match and ran. It lit up beautifully. I cycled up the burners and ran some tests and it worked fine and has been ever since. Talk about built like a tank.