KTM 950A - Mystery overheating - please help before RR!!

[navigator]

At 30 000kms the waterpump seal was replaced. However it became clear that the seal was leaking long before we became aware of it - I just kept on adding water - sometimes stream-water in the Baviaans. I also thought the watermarks on the side of engine was road grime.

Long story short:

1. Seal replaced and waterpump replaced
2. Bike kept overheating.
3. Checked thermostat
4. Checked heads and gaskets
5. Cleaned radiator (lot of gunk because of shit water etc!)
6. Swopped radiators with other 950
7. Swopped instument cluster to check for false readings
8. Checked inside of hoses for de-lamination
9. Checked water ports in engine where the ports were visible to the normal eye

Please give me your ideas - however basic or wild it may sound!!

I am desperately depressed!!!!!!!!!!

 

[Nigel X]

 

[Plothond]

 

[navigator]

 

[funacide]

 

[Adventurer]

 

[navigator]

 

[SGB]