Guys,
I too have a recent production 617 (Bought new in Dec 2010) that does the same thing as the original posters gun. Major lead/powder build up around the forcing cone, and on the top strap.
I hate the clean up, but what makes the problem worse is the fact that I *sometimes* get hit in the face with small bits of lead/powder after shooting only a few cylinders through the gun. This has happened since new, and gets worse as more and more crud builds up during a range session. The crud is not easy to clean off, so it's hard to do anything about the build up while at the range. The gun is accurate, and I can't detect any timing problems.
I suspect to correct the problem the forcing cone will need to be re-cut (it's probably not cut at the proper angle, creating most of the leading,just a guess on my part ) and the barrel to cylinder gap evened out. (it's .007 on one side, and .009 on the other, if i remember correctly. i'd have to get out the feeler gauges to verify those numbers)
I've been debating on sending the gun back to the factory to try and remedy this problem, but with all of the current quality control issues (some of which I've experienced personally) I'm a bit afraid it will come back in worse condition than it is right now.
I know many of you are saying that this type of thing is 100% normal for .22lr revolvers, but I just bought one of the new Ruger SP101 .22lr revolvers several months ago, and I can shoot hundreds of rounds through it without ANY significant lead or powder build up on the forcing cone or top strap. Based on this, I KNOW the issue with my 617 can be corrected. I just don't know if S&W is WILLING or CAPABLE to do it, at this point in time.
James