cra5h,
First ,if you don't get something working by nextweek , you can still ride just ride in moderation. Riding through water like your avatar shows, its dispersng the heat far better than the fan/ air flow ever would. You still have a over heating sensor to keep an eye on as a fail safe. Riding trails at slow speeds will cause it to get hot , but moderate to fast, you'll get plenty of air flow , just watch your sensor and let it cool down every so often .
As for relocating the oil cooler, here's my $.02 worth. If the primary purpose is to play in the mud then sure go for it, but I only seeing it adding clearance for mud and water. If using in heavy woods, mounted on the front rack could expose it to branches and oil leaks, oil leaks all over the front of your Foreman. Given that, Currently the oil cooler is in basically the safest place on the frame. Its far enough back to help keep sticks out of the cooler from the front . The Stock fan really only blows air across the crank case and not the heads, and has very little air pull through the oil cooler. I added a oil cooler fan, wire to the stock fan and sensor. It will come on when the sensor closes the curcuit , or I can manually turn on both. Its not that big of a deal, its just adding a switch to ground.
Relocation of the oil cooler:
I've had mine stripped to just the frame/motor several times on my mod's. To relocate the oil cooler to the front rack , you will need to make fab a mount , I would mount the cooler flat, with the oil cooler fan on top, blowing down through the oil cooler. DC fans can be wired to run in either direction , so if later you want to changed it to suck air through, you just reverse the wires. I choose down through doe to clean air passing through and dust dirt not blowing up in my face . I would look at HomeDepot/Lowes/Ace to find a rubber gromet about 3/4" . You can cut/drill a hole in front fender under the rack , insert the grommet and route the the oil lines through it . You can have oil lines made, or get hose barb to screw to the original oil line & oil cooler . You could use trany line and hose clamps. I would look at T-Bolts though. Add some wire loom over the lines to protect them and zip tie to secure the lines.
NOTE: check your oil after you have ran it , you going to have to add a little.
Go to eBay and search on item : 330088601046
HINT : did best offer 20.00 each . Several other people here have got them for that price.
If you are going to swap out your stock fan , I would also use one of these fans . Actually thinging about it, I would fab a mount where the oil cooler was and mount x1 of these fans and also mount x1 where the stock fan was. These fans are sealed 12vdc and I've had no problem with mine. Since mud and water will be the environment you are playing in, I would wire both fans together, with a master kill/on to disable it when going in to the water or heavy mud. This can be done by adding a SPST switch between the power feed and the fan power lead wire. Wired this way you disable the fan and it can't be over riden by your manual switch
As for increasing the air flow, you are still going to have restrictions due to the bash plate and skid plates , but x2 230CFM fans running, 1 blowing across the cylinder head and x1 on the crank case , You aren't going to have a heat issue .
NOTE: Get a manual for the schematics ..
Hope that helps,
