Any time gears are changed (spur and clutch bell), even if for the same size, it should be re-meshed. There are way to many variables that can cause the mesh to be bad if you don't.
FYI, HPI has most if not all manuals on their site. ;)
https://www.hpiracing.com/assets/documents/instruction_manuals/115871_vol02_rtr_savage_flux_hp_060315.pdf
Read through the manual, several spots in it that reference different programming items for your ESC.
Wouldn't that rotor cut the heck out of any of our standard pads with the edges on those slots? It looks like perhaps it's supposed to be a replacement for the red fiber setup. Not worth the money in my eyes, but if you give it a shot make sure to write a review.
Did you remove the carb lock as well as the screw?
Looks something like this:
Is so, just twist the carb back and forth until it pops off, they can be stubborn sometimes.
Wow, that might be the worst looking filter setup I've seen. No wonder you want to completely gut and clean that engine. I would too!
Hopefully the engine is revivable!
Congrats on the purchase! Ask any and all questions you have while going through it.
To start off, what are your goals for this Savage? Is this a budget clean up and run sort of situation? Or are you planning to upgrade and spend a bit of money as you go through it?
Those clutch shoes...
Not sure I've ever broken an engine in at "flush" settings. Usually they need some level of leaning out to start and run consistently. This is going to be a feel kind of thing for each engine. You want to lean it out just enough to get it to start and run well. Usually like 1/2 turn leaned...
Looks like you have an F4.6. Here is the manual for the engine. You can buy the o-rings with the needles. The carb as a whole. Or the engines o-ring set.
https://www.hpiracing.com/assets/documents/instruction_manuals/111598-f46_v2-glb-m-v1.pdf
O-ring kit...
I agree that they should be upfront about what the situation is before return. But, in truth, you should understand that before return as well. I wouldn't have returned it without knowing what the options and course of actions could be.
Also, there is a difference between inspect/ test and...
As you say, it's a two year old product. Not all manufacturers have the ability to do repairs in house. Likely what occurred is they received the ESC, saw the issue and issued you a quote for replacement.
Unless they specifically told you that the unit WOULD be repaired, this seems...
There are presently two on ebay. One Hybrid bulkhead and one Super hybrid bulkhead.
https://www.ebay.com/sch/i.html?_from=R40&_trksid=m570.l1313&_nkw=flm+savage+bulkhead&_sacat=0