You should see the "fix" that was done by the previous owner. It's quite the mess of teflon tape. Quality stuff...

 

I ordered the hose assembly from t-stat to water pump. Usually runs about $65 for the entire assembly. 180 t-stat is about $75.

 

Well i started to hack away at my grille












Some bending and cutting.










And this is what i have so far, im going to fill in and sand the left and right sides with sandable putty to get a uniform look.

 

now you have a saudi grill, what is that with a drive shaft and a donlop on it in the back ground?

 

That's the second rear diff that i blew up and an extra front end setup for my wife's 06 zx6r.

 

very nice

 

nice bike! Did that year come with the 636cc motor ?
I'm currently downsizing the last of my bikes at my wife's "request".

One thought in addition to the grill mod that may work for you, and depending on where your overheat scenario is occurring, is to go with Hood Louvers.

I ordered a set of these RunCool Hood Louvers - Hood Vents For Your Vehicle - Cool Your Engine for my D2. The cooling system gets overloaded when I climb hills, mostly due to all the crap I bolted onto it. The additional profile of the rack and roof top tent also doesn't help much...

The order of work should definitely be:
1: Cooling system inspection and replace/ fix as necessary (hoses, fan clutch, water pump etc etc)
2: Install the TD5 thermostat (180 degree stat)
3: Upgrade fans/ Increase air flow through the front of the truck.
4: Provide location to exhaust engine bay heat.

I'm really curious as to whether your Saudi grill lowers the temps that you see. I might do that this weekend

 

Not too bad if i do say so myself.






Her bike is 636 btw.

Funny thing i was looking at this last week WideFlow Powder-Coated Semi-Gloss Black Hi-Flow? - Hood Louvers | RunCool | Hood Vents For Your Vehicle -

 

looks great! I have another thread started trying to figure out the width of the raised hood section on the D2. do you mind terribly measuring yours? I'm going to pull the trigger and order the wideflow

 

Around 40'' at the bottom and 58'' at the top didn't get the length because mt tape measure broke