Thanks Danger4u2 4 chiming in on the KLR650 I was kinda thinking that way as an option & was a little suprised I wasnt getting any input for it on a kawaski site. Granted my heading. The xr650r really would be my 1st choice if it wasnt for the fuel range , from what I'm hearing they get about half the mileage on fuel, seems odd, must be a hotter cam stock. The ktm525 kinda calls to me but the thin seat of the newer bikes just sucks. Like ID KX500 commented "oil cooler" is a must. If I heard the oil boil like your talking about, oh man, it'd be so hard not to tear it down for fear something was messed up inside. Since I asked this question I've found an xr650l section on advrider.com, but they say it overheats on the freeway above 80mph when you ditch the shrouds & ad a bigger tank, the tight stuff is supposed to be ok though.
Thanks again for the link to advriders, Motorrad, just a great site. Some of the most awesome pics I've ever sean. I've definitly thought of the xr500 & you can about steal them $ wise. My concern is displacement

, & the older bikes can be a bit of a challenge to find common wear parts like the chain slider, guide, cable's, electrics & higher cost for the parts when you do find em. I will search on it a bit tonight though, as I haven't yet. Gotta search rebuild parts bigger tank & the odds & ends to get it in shape and keep it going.
Thanks again guys I appreciate all the input & if theres a DS bike I'm not thinking about you'd reccomend feel free.