Yamaha Aerox moped mayhem preparation

[Gazdaman]

As the title, this bike was bought for £60 to transform for any moped mayhem type events running this year. Main one in mind is the 'supermotopedathon' run at RAF Wittering as that's what I've entered last year.

So this is how I picked the bike up from a kindly BCF member

https://www.gaz-racing.co.uk/images/vehicle_1275.JPG

and quickly began stripping it apart

https://www.gaz-racing.co.uk/images/vehicle_1278.JPG

To start with my team-mate and I had massive plans for USD off-road forks and rear suspension, 12" wheels to increase tyre choice massively and knobbly tyres.

We were planning on a pitbike front end, which would mean pitbike Yokes, forks, wheel, axle, spacers, caliper and bars. And probably getting a new stem machined to suit the frame.

So we bought a 12" wheel from a Speedfight as it looked like the right PCD and should bolt straight on.

https://www.gaz-racing.co.uk/images/vehicle_1290.JPG

Of course it didn't.

https://www.gaz-racing.co.uk/images/vehicle_1355.JPG
https://www.gaz-racing.co.uk/images/vehicle_1360.JPG

Then I wasted a good part of my life designing and fabbing an adapter to fit the new wheel. Once I'd made the prototype I realised it would push the wheel off centre by about 2 inches which would make handling simply horrible.

So we decided to abandon the 12" wheel, and the posh front end. We were losing sight of the aim of the competition. So we decided to keep it cheap and work with what we had instead.

https://www.gaz-racing.co.uk/images/vehicle_1302.JPG

We'd picked up a bargainous race exhaust off eBay and I set about VHT painting it.

https://www.gaz-racing.co.uk/images/vehicle_1446.JPG

Then it was time for a top end rebuild. The bike has 10k miles on it, and no idea if it's ever been done. From the state of the old barrel I'd suspect not. We went with stock displacement to stay within the rules.

https://www.gaz-racing.co.uk/images/vehicle_1452.JPG

And the lump got a lick of paint.

https://www.gaz-racing.co.uk/images/vehicle_1454.JPG

Then it was time for the frame to go on a diet.

https://www.gaz-racing.co.uk/images/vehicle_1460.JPG

and the pile of bits for powder coating has grown

https://www.gaz-racing.co.uk/images/vehicle_1464.JPG

I'm planning on keeping the bike road legal (without any bodywork) so once this is all over I can get either a daylight MOT, or lash up a very minimal headlight and go from there.
I've found a good local powder coater that does it all nice and cheaply, so I figure why not.

Only thing we need to do before coating is to brace up the frame like so

https://www.gaz-racing.co.uk/images/vehicle_1465.JPG

Then it's reassembly. There are a few new bearings and seals and things to go on as its reassembled, but nothing too major.

The stock fuel tank sits behind the rider's seat, it's not massive, and it's a fair bit of weight in the wrong place. So I'm planning on relocating a small go-kart type fuel tank into the under-seat storage space. It'll bring the weight central and low, and it'll mean I can ditch the standard fuel tank. (Which would be useful since I killed the fuel cap). So I'm on the lookout for a go-kart or generator fuel tank that'll fit in a 9" x 8.5" gap, but must be gravity fed unlike a lot of go-kart tanks.

Then add number boards, hand guards, some sort of crash protection and some 13" knobbly tyres (which do exist).

Then run it in, play with jetting, mess with the rollers and clutch springs etc and race it!

Gaz

[SpannerMonkey]

I wanna join on on this mopedathon! Pleaseeee?!
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My bike? A YX140 powered one-off Monkey Bike, something a little different!

[speedy]

hey nice looking project..if the original forks are in good condition then keep them as the stock rox forks are very good and it sounds like you'll waste a lot of time and money on usd's may be it'd be worth doing a couple track days or something with stock forks on to see how they feel
also have you thought about getting a tank made to fit in the seat or is that too much weight

whats the rules on the engine spec i.e do you have to keep to a certain cc or a certain level of tuning
if its just a cc limit why not split the cases and do some flowing and possibly port the barrel a little then go for a bigger carb as the standard is very small iirc

what exhaust is that?

[Gazdaman]

The exhaust is a Technigas. But really we only got it because it was the cheapest on eBay.

Capacity limit is 50cc for 2 strokes.

Supermotopedathon hasn't been announced yet, but the key is to find a crap ped and get going!

The stock forks aren't in great condition, but they're definitely salvagable. I am planning a trackday at the local go-kart track once this is done. I've got a two bike trailer, and I'll need to take my pitbike, so I may aswell run both.

I'm not too worried about weight for a fuel tank, but having one made would be added cost. I'm hoping I can just get one suitable that'll fit. It's very spacious under the seat, with a 9" x 8.5" gap that must have about 8" height.

I had thought about flowing etc, and in an ideal world, with infinite time, I would. But I've not even split the cases, the engine runs and runs quite well. So I've decided to leave alone for now. Long term I'll pick up another engine and do a proper job on it, replacing the main bearings (maybe the crank too) then powder coating the cases etc. That would be the ideal opportunity to flow and port and polish etc.

The only tuning we're going to be doing on this is the race exhaust, maybe a free flowing air filter and jetted to suit.

Gaz

[SpannerMonkey]

Awww Mines four stroke
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My bike? A YX140 powered one-off Monkey Bike, something a little different!

[Gazdaman]

It's 90cc limit for 4 strokes.

Really you need something cheap and shit. The cheaper and shitter the better.

Gaz

[Nope.]

Wanted to do one of these for a while. Just need to find a crap moped first!

Are these usually charity events or somthing?
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Former: Derbi GP1 50, Sachs XTC 125, Suzuki GSXR 400 GK73A, Kawasaki ZX7R, Suzuki DR250, Yamaha RD350
Current: 2011 Yamaha XT660Z Ténéré, 2003 Yamaha YZR-R1 5PW (In Build), 2009 Kawasaki ZZR1400

[dextersaurus]

should get the frame done bright yellow/pink, and get a leopard print seat cover for it.

Fantastic work so far. i'd love to get involved in one of these

Dunc

[Gazdaman]

[retrobiker]

looks a fun project... will be watching this one

[dextersaurus]

[Gazdaman]

Because we're talking race 'peds boi, this aint no joke!

(Loosely based on a Fast and Furious quote for those playing at home).

gaz

[Shaft]

[Gazdaman]

There aren't really any rules. Just think about it in the spirit of the competition and it's common sense.

No pit bikes, or small MX bikes. It's got to be a proper ped really. Then it's a capacity limit (some allow different capacities depending if it's manual or auto gearbox).

I have seen those fuel tanks, I don't think the shape would be right for the hole.

Gaz

[Gazdaman]

https://www.gaz-racing.co.uk/images/vehicle_1477.JPG
Bracing box section cut and offered up

https://www.gaz-racing.co.uk/images/vehicle_1478.JPG
Welded

https://www.gaz-racing.co.uk/images/vehicle_1479.JPG
Cross brace added

https://www.gaz-racing.co.uk/images/vehicle_1481.JPG
https://www.gaz-racing.co.uk/images/vehicle_1482.JPG

Ready for powder coat!

Gaz

[speedy]

projects like this make me smile I hope to do similar some day

[Gazdaman]

Frame, handlebars, both wheels and two engine covers were dropped off at the powder coaters this morning to be collected on the 16th of next month.

It's all going a very BCF orange.

Gaz

[MarkJ]

Gaz, how much are you paying for powdercoating all that lot? Are they also doing the sandblasting and did you mask off all the threads for them?

[Gazdaman]

It's £100, I chucked a mountainbike frame in to be done too. They do all the shotblasting and masking.

They did my ke175 chassis, so I know they're of a standard.

Gaz

[MarkJ]

Christ, that sounds cheap, all the ones with websites that specifically do bikes say that just a frame can be £100-150! Is this just a normal powdercoaters that does fencing etc.?

[Gazdaman]

It is cheap, I think they mostly do industrial stuff like skips and railings etc, but they do advertise doing bike/kart/kit car chassis.

Their customer relations isn't great. Both times they've done stuff for me they've not got in contact to say that the parts are done, and when I've contacted them to enquire they've been like "Oh yeah, they've been done for AGES!".

But they do a decent job, and it's cheap, so I'll keep using them, if my biggest grumble is I have to phone them, then so be it.

This is them: https://www.newtechpowder.co.uk/

Gaz

[aerox12]

ive just fitted a 70cc kit on my 08 aerox, the timing is all wrong and it keep cutting out! it wont start first time! feels asif somthing is holding it back!! HELP


and could anyone tell what the two gold things are coming from the top of the cylinder head by the thermostat???
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help

[Gazdaman]

[Gazdaman]

Chassis' back from the powder coaters!

Gaz

[MarkJ]

All that for £100, looks a good job too