Panhead1, sorry to hear about your problems. Your pistons should be at no more than .0025. I had a similar problem with a brand new S&S 107. Sounded like valve train noise from day one, but not that bad so I rode it for 2k miles after break in. At about 2 k miles it was banging like you wouldn't believe and honestly if I had to bet money I would say it was valve train noise (I have commented about this before). Also if you listened really closely( I also use a short piece of tubing for this) you could hear a small knock just off idle coming from the cylinders. I took it to a S&S authorized repair shop and after only two months of back and forth with my mechanic S&S agreed to pay him to pull the entire motor, take it back and redo it. It was under warranty, so it really sucks that they gave him and me the run around. Got it back a month later . S&S said they had their best man on it. It ran for 71 miles , but their best man forgot to tighten the rear jam nuts on the push rods. Back to the shop. 2k miles later the same loud noise. My tech (Bennett is Long Beach Ca.) measured the piston to cylinder wall clearance. It was .0045 and .0050. S&S knuckled under and send my tech new jugs,pistons,rings, etc. He honed the cylinders to .0025. No noise at all. I would have lost that valve train bet. Anyways if you are getting a .025 feeler gauge between piston and cylinder wall the pistons are too loose and when they hit top dead center they move from one side of cylinder to the other which I suspect is the noise you are hearing. I hope my dilemma sheds some light on your situation. I am sure S&S products are mostly good. I probably just got a lemon or a inept tech at S&S.Let us know if the noise goes away when you set those pistons to what they should be. Sorry for the short novel. CAHDBIKER
I am afraid i probably found my noise in the bike. I can stick a .025 feeler gauge between the piston and the cylinder wall. pretty sure they set the bore to .025 instead of .0025 like its suppose to be. Gonna take the cylinders to a friend with a bore gauge and see what they are actually at. If wrong guess there is a wasted set of cylinders now.