Aeroplan booking itinerary help?

Call Aeroplan and theywill hep you plan. Costs you $35 if you make the bookings.

Go on the aeroplan site and search the individual segments you want to take.
Avoid flying on Air Canada if you don't want fuel surcharges.
Fly to Chicago and then see if ANA has any award seats to Tokyo.
Make stops along the way to your destinations if there are no flights available
Example: HND to SYD could be routed like HND - TPE - BKK - SYD

I booked a reward in business class for the new year to SYD, SIN, and ICN. The routing ended up YYZ - SEA - TPE - BKK - SYD(dest) - BKK - SIN(stop) - ICN(stop) - YYZ
Good Luck

From a quick search, both Japan and Australia have laws to restrict fuel surchages departing from their countries, even for direct flights on AC.

Ideally, if you can find something like Canada -> Hong Kong -> Australia -> Japan -> Canada, then theoretically you should only be charged minimal levies on any Star Alliance airline.
(Hong Kong has restricted levies for both inbound and outbound, Just transit there if you're not interested in laying over)

You can probably stick in Bali in the middle somehwere?