Well after rechecking the adjustment on two seperate occasions, adjusting them down to .002" and trying that, and finally putting them back at .004" on both intake and exhaust. I've concluded that the valves havnt made any noise since the first time I adjusted them when they were at nearly .009" clearance. HOWEVER, I still have a pronounced tap that exactly mimmicks a loose valve adjustment, but only when at full operating temperature, and the switch from 15w40 to 20w50 made the tap less noticeable. The bottom end is quiet always, and the tap starts to be heard about 70% warmed up, and reaches it's full tap when 100% warmed up. Long screwdriver to the ear hasnt revealed anything. Listening around the engine it sure seems to be localized around the valvetrain area. I've put nearly 400 miles on it soo far, and the tap hasnt changed. I've poured through the parts schematics for everything at the top end looking for a culprit. Though I have little experience with bike repair, I have been an auto and equip tech for nearly 20 years and my gut says something has excessive clearance, and the cooler (thicker) oil is masking it till it gets warmed up. I did recently check the decomp lever adjustment, and verify the rocker arm was not contacting the decomp shaft while running.

Wheels....just a suggestion.... head out to a dealer and ask to test ride a new one....listen to it and compair, or find a used one that has been "checked" by thier mechanic and ask to listen to it. Think that will help? I'm with you tho, been playin' with the wifes trying to make it safe enough for me to turn over to her and I think it still sounds too noisy, was about t do a valve adjustment myself.