When I ride for lomg periods of time in fairly hot temps. the puke bottle fills up then it pukes. After it cools I open the raditator cap, drain the bottle and pour it back in radiator. Just to find later the bottle filling up again. WTF! any ideas?

 

It sounds like you have a blown headgasket.

 

Head gasket...

 

This bike doesn't blow any smoke and there is no oil in antifreeze. any other ideas?

 

it doesnt have to blow smoke or have antifreeze in the oil to be a headgasket problem, but it could also be the radiator cap not sealing

 

As warrior007 said. Also, does your Radiator fan ever come on? Check the thermostat also.

 

I had the exact same problem as you. So I traded radiator caps with another raptor. It seemed to fix the problem. So I would suggest trading radiator caps with someone else first before you tear it down to the head gasket.

 

the motor is tore down already after the piston cracked due to flex from a defective wrist pin (too short).
nothing was loose or leaking, the fan does come on periodically but not for very long, no water in oil

 

I've already gone through the stripped cylinder bolts and installed the inserts to correct it.