Still sounds like an ACR problem to me. If you get lucky and the pistons are on the exhaust or intake strokes when you hit the start button, the starter can probably attain a fast enough first spin to fire the engine normally. If it doesn't fire immediately, or if the pistons are on the compression stroke, the starter hits instant resistance and may not spin quickly enough to fire up immediately, leading to kickback and a puff of smoke.
It would have been nice if H-D had located the ACR's where you could actually see and access them, but that's like lots of other things that would have been nice if H-D ever got their heads out of their collective rear ends. A competent shop should be able to quickly diagnose and rectify this issue. If you can't find a competent shop and get tired of all the BS, you might want to consider swapping cams to something with a little overlap to reduce that cranking pressure and then eliminate the ACR's. You wouldn't need them if Harley hadn't gone with the 255 cams, since static compression is only around 9:1.
JMHO.
Jerry