Wow thanks guys. I have been around dirt bikes for many years, but never had one sound like this.
Performancecycle, I too found that the more I leaned the bike out the less noise it makes. It is almost like if you are riding in that nasty 1/4 throttle range under very light load it hammers like the piston is knocking, very scary sounding.
I did check the KIPS in more depth. Per a suggestion I found while searching this site!

I removed the plug on the left side of the cylinder and turned the main shaft with a socket, then through the exhaust port I could see that all three valves are in fact moving like they should. I also noticed that the shaft turns nice and easy and smooth, and will snap back in position on it's own.
So I really think this top end is in good shape. Piston looks good, what I can see of the cylinder through the exhaust port looks good, good compression and power valves all move properly. I guess we need to start riding the bike and quit worrying about it.
Thanks to all of you guys and your support, you have made this a much easier project. And thanks for being so patient with me and my dumb questions. You guys ROCK!
