2005 Yamaha Aerox 50cc Wiring diagram

[Deleted]

Hi Guys

Looking for a wiring diagram for 2005 Aerox
I can only find the 97 wiring diagram but they have changed the CDI/Stator wiring after 04.
I'm swapping the LC Aerox engine into a Vmoto Monza/Vento Triton and want to make sure the wiring is correct.
If you have any tips aswell please let me know


Sorry if this is in the wrong section
If you have it please upload it publicly as all the forums are filled with "PM me ur email"

Thanks

[Lucass2T]

Did you try a MBK nitro, Neo's or Ovetto scheme? Those last two might share a lot with the aerox?

[Deleted]

Had a quick look but couldn't find anything.
This cdi is weird
www.pedparts.co.uk/blog/aerox-cdi-testing-no-spark
This article has some good info on it
It's becoming difficult to figure out how to adapt a 4pin aerox magneto and cdi to the chinese electrical system.

[ryan_ott]

I believe the stator from your current engine (minarelli clone) will mount on the Aerox engine, as will the flywheel if it is the same small taper. That would save you a lot of wiring trouble. It looks as if the newer Aerox is a dc ignition judging by the amount of coils the stator has.

[Deleted]

Hey Guys,

I think I've translated it correctly now.
I'll wire it up and see if it sparks
If it does i'll post the diagram.

I didn't want to swap the stator as i believed the yamaha parts would be of better quality. I might have too though.
Yes, the 04 and later Aeroxs use DC power which I find odd.

[Deleted]

Heres a pic of the aerox engine in the Chinese ped.
It actually fits perfectly.
Doing the cooling system is going to be the hardest part.
I also need to figure out how I'm going to change the front wheel as the axles are different sizes.
I could swap the fork (to the aerox Paoli suspension) or maybe just change out the wheel bearings. Not sure yet

[ryan_ott]

The Aerox forks maybe longer and may take some work to get the bike to sit level. On my Zuma that was the case. For component quality, ignition parts from a Zuma would work if you can’t get the wiring figured out.

[Deleted]

Yes, I already tried to fit them but the aerox forks are 1mm less in diameter and they also mount different.
The aerox forks have a circlip at the top instead of a bolt like the Chinese ones.

[ryan_ott]

You could use .5mm shim material to make up the difference. The bolt or clip at the top shouldn’t matter it’s the pinch bolt that holds it in. I’ve had mine like this for awhile with no issues.

[Deleted]

Thanks for the help!

Just to confirm, are your forks the circlip type? do you have the clip installed?
I could definitely use the shim material but the fork holder thing also has a lip on the top where the forks go through, i guess i could just grind that out though.

[ryan_ott]

My stem had a ridge I had to grind out and to fit these Aerox forks. If the length was ok I could of used as-is but they were pretty long so my solution to keep a decent ride comfort was to push them up a bit higher. Yes my Aerox forks originally had the clip but it’s no longer needed.
Let us know what you find out with the wiring.

[Deleted]

Alright so I gave up on trying to use the aerox cdi.
I'm using the Chinese magneto and cdi with the aerox flywheel. (on the aerox engine)
The bike runs and idles perfectly but at about 1/4 - 1/2 throttle it cuts out like a misfire. It doesn't stall or turn off, it just wont rev higher than that.
It's not charging the battery either.
The grounds seem okay and the pick up is the correct distance from the flywheel.

Could the distance from the coils to the flywheel be a problem? I think the flywheels are a little bit different in size.
The chinese flywheel will not fit on the aerox motor as the shaft size is different.
It does the same thing with a fully charged battery and no battery.

Any ideas?

[Deleted]

I measured the stator wires and the "exciter" seems fine at 50-70 VAC and the pick up seems to sit at 1.2 VAC

Can't see any voltage from the lighting coils

[Deleted]

Anyone??

How close does the flywheel need to be to the coils to produce voltage?

I've got the aerox forks mounted. Just need to figure out this misfire and it'll be perfect.
heres a pic, looks so much better with 13" rims.

[ryan_ott]

Are you running with tha airbox in place? If your jetting is off it could act the same way. The flywheel should be within .15-.30” of the stator, see below. The pickup coil .10-12mm or a business card thickness. I wonder if the Aerox flywheel which is designed for a dc stator won’t work with the clone ac stator.

Left Zuma, right clone







You may need a 02-11 Zuma flywheel