Hey Concho sorry to hear of your awfull dilema I am sincerly beside myself. I dont know what advice I can offer you but I would guess it is the o-ring and try that cus its a cheap fix. As far as the dealer thing I think you are S**t outa luck and for that I'm truely sorry. It's hard to imagine that a bike with a warranty can cause so many headaches. I would take it to the shop i bought it from and would not take it back untill it is fixed. have you tried cutting some of the rad guard fins away to get increased air flow to the rads as a measure to decrease excess heat? if you are having trouble with hight temp make sure you replace those ktm hose clamps with ones from your local hardware store. try not to let this get you down ......sounds like you got a blem? start with the small things then look at the big,and i'll see what I can find out.