Brown Connector Problem - Yes, we are affected

[Joe250]

There has been a lot of speculation as to whether or not our 2nd generation Tuono's are affected by the dreaded brown connector problem. It appears we are. Was working on a fellow board member's 07 with less than 4,000 miles on it and discovered this:



I have a detailed fix up here:

http://www.joe250.com/motorcycles/tu...onnectors.html

If you haven't performed this fix yet, I recommend you do it sooner rather than later.

[wavz]

Thanks Joe, but you forgot to mention that this increases horsepower by 14 at the rear wheel!


(SOB! ok, so it isn't true, just try to think that when you're replacing this sh$t and maybe it'll help the job go quicker)

[TuonoAB]

Thx Joe, good to know. I guess this will have to be one of my first projects, doesn't seem to bad, just dread hacking brand new factory wireing.

[Beau1K]

Wow Joe...great website you got there. Lots of good info.

[highside299]

As Joe stated, it DOES effect the 06-08 Tuono. Take his advice and correct it before it becomes an issue like it did with mine!!

[aka marco]

where is it ? i wanna check next time ill wash me bike.
where can i found the brown connector? is it under the expansion tank?

[MASHMAN]

Marco, there's 2... 1 under the right hand fairing near the regulator (hardly ever goes bad) but the other one is just behind the expansion tank between the V of the engine and that's the little bugga...

[Joe250]

Wow. Just checked my friend Rick's 07 Tuono R and look what we found:





He has about 5000 miles on this bike. Youch. Much worse than my other friend's bike. We decided to repair it immediately. Surprisingly, it only took us about an hour and 15 minutes total. Not bad at all. Amauri was right - pulling the wires through to the other side, repairing them, then running them back through was FAR easier than repairing the wires in place. Thanks for that!

I used today's repair pics to do a quick how-to on my site:

http://www.joe250.com/motorcycles/tu...onnectors.html

[Soot]

Joe every time I read one of your posts I start to cringebut I had a look and the connector is starting to melt, so I have a job next weekend thanks for the info.

[Priest]

Joe, DON'T SEARCH NO MORE!!!!

[packrat]

Thanks Joe!!! As usual, another GREAT "how-to" with pix....gonna go look at mine right now!!!

[Hamos]

Io if my bike has 2 brown connectors, one is located behind the coolant expansion tank and the other is located between the vee of the engine?

If just one then there is only one behind the expansion tank?

[sinex]

if this is such a problem, have aprilia done a recall?

[whiner]

Originally Posted by Joe250

There has been a lot of speculation as to whether or not our 2nd generation Tuono's are affected by the dreaded brown connector problem. It appears we are. Was working on a fellow board member's 07 with less than 4,000 miles on it and discovered this:



I should have a detailed fix up here shortly:

http://www.joe250.com/motorcycles/tu...onnectors.html

If you haven't performed this fix yet, I recommend you do it sooner rather than later.

Joe I've read your "how to" and thought what a great fix.

http://www.joe250.com/motorcycles/tu...onnectors.html

Then it occurred to me that you have not taken any notice of the circuit.

Is this OK to do?. I know that the alternator generates AC, but one of the wires must be a common or earth or something important.

Just though I'd ask before doing the mod. Like I said before great find.

[nemmetz02]

this should have a great big sticky and maybe even added to the TECH TIPS section.