Paul's Save The Aerox Project

[aeroxbud]

This bike has a lot going on so I thought I might start a build thread. The price of even very old Yamaha aerox is crazy now. So this is the cheapest NS aerox I have ever seen. I paid £700 for it but you will see why it's so cheap as the project moves along.
If I can make it good for about £1200 I will be happy.
It needs two tires, a full panel set. The bars are bent, and the steering lock doesn't work. Head bearings have play in, plus it's leaking coolant and oil everywhere! 😬

[aeroxbud]

The first thing I thought I would investigate was the CVT. It's got so many Polini stickers on it it must have some Polini bits somewhere.
Looks like we have full travel of the variator!

I initially thought it had the wrong belt. But it's a new genuine Yamaha one.
The nut on the variator is just a hardware store item. No conical washer fitted underneath. And the Naraku variator backing plate is jammed on the crank.
They had fitted a really large washer between the variator and the starter clutch. I think it had been tightened up not square with an impact, and damaged the backing plate and starter clutch.

Lucky I have some spares and the Naraku variator is an exact copy of the Yamaha variator so I used and old standard ramp plate.

[aeroxbud]

I didn't expect the frame to be so rusty behind the radiator. I guess it gets a lot of heat and water too.

[aeroxbud]

The steering lock wouldn't engage. After spending way to long grinding the bolts off. The steering lock was fine.
I guess at some point somebody tried to bust the lock by kicking the bars. Resulting in bent bars and this.

While having the stem out it made sense to change the head stock bearings.

The genuine Yamaha seal was nearly as much as the whole bearing set!

[aeroxbud]

Fixed the rust on the frame, and triple tree.

[aeroxbud]

Also changed the fork oil which really smelled bad so definitely needed doing.
As well as the front tyre.

Putting the new one on wasn't too bad. But getting the old one off involved much

Cleaned up and painted a few of the other brackets too.

[190mech]

Very nice work!!!

[pili]

I love your attention to detail. That'll be a heck of a scoot when you're done. Funny thing about Yamaha prices, some things are way cheaper than one expects and others are wow that much?

[aeroxbud]

Jul 6, 2022 20:23:07 GMT -5 pili said:

I love your attention to detail. That'll be a heck of a scoot when you're done. Funny thing about Yamaha prices, some things are way cheaper than one expects and others are wow that much?

I know what you mean. Some of the Yamaha genuine parts are crazy prices. But others you think would be expensive, not so much.
The only good thing is good aftermarket support, especially for the engine parts.

[yambw’s]

Fowlers are your freinds, right aeroxbud ?

[aeroxbud]

Jul 7, 2022 9:08:10 GMT -5 yambw’s said:

Fowlers are your freinds, right aeroxbud ?

They are a great source of genuine parts. But the steering headset seal was almost the price of a whole bearing and cups set.
I have brought a lot of bits from them before. Not all their stock or model information is up to date of listed on their website.
It was handy when the Yamaha dealer moved across the road from me. But then I had to move away.

[aeroxbud]

The ignition wiring left a lot to be desired. I'm no master electrician, but it's got to be better than before.

[geoffh]

City and guilds grade a work here ,I smell a keeper worming its way in.

Geoff

[aeroxbud]

Thought I better start to update this thread even though not much progress has been made lately. Being ill for about three months is my excuse!




This looks a bit rough. But it sits behind another panel which screws into it. Main concern was making it strong.



I used an old hand guard off a trial bike and a soldering iron. Saved £85.

[pili]

Your cleaning and painting skills are exceptional. Looks like a great project restoring a classic.