Hi,

Firstly I will confess my failure incase you are thinking the same thing....



Next !!!!!

1.        Buy one of these:-
http://www.ebay.com.au/itm/DC-12V-0-9A-3100RPM-MIN-Rotary-Speed-2-Wire-Cable-Gear-Motor-/301193482990?ssPageName=ADME:L:OU:AU:3160
$AU32 in hand (Brisbane - Australia)
       Remove fan from spigot on original motor. It just pulls off….
2.       Take note of the clearance from the end of the spigot to the flat plain of the housing outer face – see photo.
   



 
3.       Remove original motor from plastic housing and get rid of the ridges inside the housing so that the new motor fits all the way home. See Photo.  You will have to make a hole at the end of the original housing so that the new wires can come out. (I used a Dermal)



4.       Once new motor is seated all the way home, and it will fit well. Use a straight edge to work out how much you need to cut off the end of the new motors spigot. See Photo.  Once again I used a Dermal.

5.       Drill out the hole in the middle of the fan to allow the new spigot to fit – don’t go to big – it needs to be a tight fit.

6.       I used silicon to mount new motor back into original plastic housing, it fits very well – See photo. 



7.       Push fan onto new spigot – make sure that it can spin freely when fan is placed face down on a flat surface or it may munch into your radiator (not good).
 
8.       Be aware of the polarity when reconnecting the wiring – remember you want the fan to SUCK not BLOW, this means you may need to swap the red and the black wires over to get the right air flow direction out of the DC motor.
For those of you that are more Technical than I – note – the new motor is specked at 3100RPM, the original is specked at 4500RPM. If someone sees a big problem with this please let me know, I life in very sunny very hot Brisbane Australia – if anybody is going to have a problem with the slower fan speed then I guess it will be me – I must say though – she really sucks! I do not see a problem.
I hope this helps – I know I had a big problem buying an original motor knowing full well the design is floored to say the least (and no replacement brushes!) Not to mention the cost…….

Keep the shiny side up boys and girls…….

Works very well !!!

Take a gander at this Spal 6.5" fan conversion (which I've done to my bike as well). 
Cannot relate how pleased I am with the improvement: quieter, far more air movement and a lower profile for enhanced circulation. 

A bracket can be made easily from aluminum (found on other thread on same forum).

Kyle10 wrote:Take a gander at this Spal 6.5" fan conversion (which I've done to my bike as well). 
Cannot relate how pleased I am with the improvement: quieter, far more air movement and a lower profile for enhanced circulation. 

A bracket can be made easily from aluminum (found on other thread on same forum).

Yep !

Looks great, I would have gone that way.........