Are you sure you got all the air out of the cooling system when refilling it. Did you take the little plastic bolt out of the left side rad to get the air out of that rad? You might have had air trapped.

 

Nuts!!!! I looked for a bolt on the left side rad (my old KDX250 had one), and I couldn't find one (which I thought was odd). Where exactly is the bolt located? Nothing was mentioned in the manual.

 

Just take the top radiator hoses off or stick a screwdriver under them to let the air out, fill till it starts coming out.

 

I've also been able to tip the bike over on the left to get the air out of the left radiator.

 

So I finally got around to replacing the head gasket. I also checked my valves. One intake was out of spec (way to tight), and all the others were really close to the bottom end specs. Anyways, I changed all the shims. Everything thing is in spec (but on the high end). It was amazing how easily it started in the cold. Went for a good long ride, no coolant issues, no oil leaks. I guess it was just a faulty head gasket. BUT, man, is the bike ever noisy now, I guess that's from the valves being adjusted.

 

Good to hear man. Glad its all running and working fine.