This was all done on a 2009 GG so earlier bikes may differ slightly on the removal and refit process for the radiator and fan assembly. The fan motor change-out should be the same though. This whole process was easy and took about 45mins. The motor was £11 including next day delivery.
Sorry but I can't work out how to put the pictures in the right order or place. Maybe Andy will edit it for me. Picture four shown the complete assembly and the new motor.
Remove the radiator and fan from the bike.
This is easy enough and only requires the tank taken off, remove the coil bolts, disconnect the CDI unit and pull the wiring out of the way to gain good access. Remove the top and bottom radiator hose clamps then the two screws holding the bottom and one holding the top of the radiator to the frame. Disconnect the thermostat wiring at the connector in the wiring loom and also the final remaining connector to the fan. The whole thing should now pull out to the left hand side of the bike.
Remove the fan assembly from the radiator.
This is pop riveted in place. Using a drill, drill out the two pop rivets being careful not to drill down in to the radiator matrix.
Remove the water/dirt seal.Picture three
This rubber boot is actually glued on so you have to peel it back the best you can and use a sharp knife to gently cut the between the body and the rubber to remove it without cutting through the boot.
Remove the old motor.Pictures 1 & 2 (Note picture two shows how to hold the unit while punching out the shaft. It wasa taken after the fact so shown bottom of motor knocked out.
This was the bit I was unsure about. Place the fan assembly in a vice and using a small punch (I couldn’t find one in the garage so used a ground down nail) hammer the shaft out of the brass bush. It was pretty stiff even after heating with a fine torch. In fact it was cold when I finally decided to hit it harder and it started to move. Part of the reason is that you are actually hammering the shaft out of the motor at the same time (i.e breaking it). There is no other way as the screws that hold the motor to the body are under the fan. Anyway it came out pretty easily once I was confident enough to hit it. Once the fan is out unscrew the two screws holding the motor to the body and withdraw it. Picture 5 shows the two screws that hold the motor to the unit underneath the fan.
Unsolder the wires.
Self explanatory really. Just unsolder the two wires and through the old motor away.
Now reassemble in the reverse order. But before you start take note.
1. There is no indication on the old or new motor which terminals is which so I connected a DC power supply to them to make sure I got the motor direction right before I resoldered the wires to the new one. A 9v PP3 or 12v car battery would do if your stuck. On my bike the wire with the red strip was the positive but your may be different.
2. When you come to hammering the fan back on the new motor you MUST make sure your don’t just do as you did taking the old one out and destroy the motor. Make sure you place the back end of the motor shaft on something so that your hamming against it or you could just push the motor part hammering it together again.
3. Finally glue or silicon seal the rubber boot back in to place before refitting it to the bike.