Ihave been thru this hell aswell.
I emailed a lot with Kemper Support.
The problem is that with FW 1.05 you can not have more than say 500 rigs in the KPA. More = it freezes as your did.
They are working for a solution in next FW that should not be far away.....I hope.
In the mean time I did as you, erased the flash memory and went back to 1.04.
Now I go thru all Rigs and delete or backup the ones I do not want to use.
Problem is, this morning I deleted about 20 Rigs. Went out shopping and when I got back there were 45 new Rigs to download
Mike