Ugh, man; what an ordeal! I hope *this* time is *THE* time for you!!
Checking T-stat housing halves for flatness seems worth doing, regardless. I mean, I have the coolant drained and things taken apart anyway.If you have a leak again and I hope you don't, I would suggest removing the T stat housing and check both halves for flatness. My housing was showing signs of a leak but not as active as yours. I placed 400 grit wet/dry sandpaper on my table saw (counter top will do) and polished both halves flat. The outer cover took a bit of work before it shined up across the face. It is also important to draw the bolts up evenly when installing the cover.
I like RTV but not in this situation. I would recommend Permatex form a gasket #2 or Permatex aviation form a gasket to provide an additional seal to the metal faces of the T stat housing. Both are rated to 400 degrees and are compatible with water and ethylene glycol.
Thanks, it's been annoying as hell. I'm really tired of smelling hot coolant almost every ride, and finding streaks of dried coolant on the engine case and a sticky green mess in the bottom of my skid plate.Ugh, man; what an ordeal! I hope *this* time is *THE* time for you!!