Well I put it back together, checking the valves a few times as I went each step of the way, checked after I out the caps on, checked after I properly torques the cap bolts, rotated the crank a few times and rechecked. The whole time all clearances were in spec. Put the valve cover back on, plug, hoses, carb, then the gas tank and seat. Went to kick it over and I can't move the kickstart!!!

so now I'm back to square one, just hopefully not too much worse off

tearing it down tomorrow and rechecking EVERYTHING!