Pushrod length sound right?
I am sure you have checked and rechecked, but be doubly sure the rod is in the cup and not up on the rim.
The other thing to be careful of is that the lifter is in contact with the cam. If you are rotating the motor while doing this you have to push the lifter down after any lifter movement. There were a few times when I did mine that I actually rotated the motor just to push the lifter up so I could actually hear it contact when I pushed it back down just as insurance I was in contact.
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