Just trying to brainstorm here... I've never replaced the oil cooler on my bike, but I have replaced water pumps and coolers on trucks/cars. Does the oil cooler on the bike come with the red caps inside the water lines and if so, do you remember removing them? I'm just checking the obvious, because it seems like everything else has been covered here and you are still having a circulation problem.

 

my fan comes on at 219F - is that a problem? I thought you said that was normal...

 

The fan does come on at 219, 170 to 180 is considered a normal operating temp, that's when the thermostat opens and lets the coolant start to flow. Of course, this means that the bikes will run hotter than 180... hell I rarely ever see below 200 on mine.

 

here's a diagram of the oil cooler
http://houseofmotorcycles.bikebandit...R+CBR600RR.asp Its part number 9. nothing special with it. just 2 coolant hoses coming into it. Honestly i think i just need to bleed this thing a little more. I checked it out this morning and the coolant in the reserve tank was down to the bottom. So im thinking this thing still needs more coolant added. A lot more coolant probably spilled out than i first suspected. If any more idea's come up let me know. Thanks again for the help!