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Thread: Brown Connector Problem - Yes, we are affected

  1. #31
    apriliaforum expert JodyH's Avatar
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    Quote Originally Posted by Joe250 View Post
    Jody - would you mind telling us about what serial number your bike is? I'm suspecting it has more to do with that than the color of the bike, but who knows.

    Thanks.
    I still think the matte blacks are made by magical Italian elves... hence are superior.
    But if you think the serial numbers have anything to do with it...
    ZD4RRTT097S000303
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    "Nihilists! Fuck me. I mean, say what you want about the tenets of National Socialism, Dude, at least it's an ethos. "

  2. #32
    apriliaforum Junkie rmcobb's Avatar
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    Quote Originally Posted by JodyH View Post
    I still think the matte blacks are made by magical Italian elves... hence are superior.
    But if you think the serial numbers have anything to do with it...
    ZD4RRTT097S000303

    Mine only has the one connector as best I can tell as well. Its an 07, purchased in Dec 06.

    ZD4RRTT087S000440

    The bike has 5000 miles on it and the connector looks fine. Not that that means much according to quite a few of you. I'll be chopping it out to be safe.

    For those bikes that have 2, is the second brown connector still being used by the 3 yellow wires? In other words, they used 2 while going from the Alternator to the Voltate Regulator??
    [

  3. #33
    apriliaforum Member Joe250's Avatar
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    Quote Originally Posted by rmcobb View Post
    For those bikes that have 2, is the second brown connector still being used by the 3 yellow wires? In other words, they used 2 while going from the Alternator to the Voltate Regulator??
    Yes, the wires coming off of part #8 below pass through the V of the engine and attach to....




    ...part #3 in this picture. Finally, that wiring then connects to the voltage regulator (part #4):



    For those with only 1 brown connector, it appears the wiring coming out of the alternator (part 8) is longer and reaches all the way to plug directly into the voltage regulator (part #4). So these bikes will not actually have any extension (part #3).

    Due to some problem with the electrical connectors inside the brown connectors, excessive resisted is created, generating excessive heat. So by simply cutting out the brown connectors and reconnecting the wires with butt connectors, the problem should be avoided entirely.
    Last edited by Joe250; 03-25-2008 at 01:22 AM.

  4. #34
    apriliaforum Member Nixter's Avatar
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    Just checked my 07.5 and it looks fine at 4k miles. I will be keeping an eye on is though.
    2007.5 Black Tuono R - Cox Racing radiator guards, Powerbronze & Laminar screen, Pazzo shorty levers, 15/43 gearing, Woodcraft sliders, AF1 link plates, Hella horn

  5. #35
    apriliaforum expert toycloser's Avatar
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    my vin# 7s000065 (usa) built in 01/06 and has the extension on it.
    Current Aprilia: 2006 Caponord
    Previous Aprilia: 2007 Tuono, 2009 Shiver
    Worst crash: 2007 SVX 550 (blown motor)

  6. #36
    apriliaforum expert wavz's Avatar
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    I'm swinging by the electric shop today to get the stuff I need, so far I gather:

    wire strippers (with all the money i spent on strippers you'd think I would pick up a wire one)

    Crimpers - I suppose a decent pair that can be calibrated appropriately
    butt connectors - any specifics on this?

    14G wire - are we using a high temp? I'm not sure what kind of wiring those yellow wires are but it doesn't make too much sense using "better" wire to connect the two ends of yellow wire that will remain.

    Heat shrink and protective sheathing.

    What is the route everyone is taking when they do the reroute? It doesn't make much sense to try and push it back through between the cylinders if there is the chance I'll have to mess with it again. I figured I'd run enough wire to run it in front of the front cylinder, away from the headers, to get it over to the LH side.

  7. #37
    apriliaforum Junkie rmcobb's Avatar
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    Quote Originally Posted by Joe250 View Post
    For those with only 1 brown connector, it appears the wiring coming out of the alternator (part 8) is longer and reaches all the way to plug directly into the voltage regulator (part #4). So these bikes will not actually have any extension (part #3)
    Yeah, when you look at the schematics, the alternator has 2 different part numbers. One for Model Year 6, and another for model year 7 and 8. Not sure if the VIN#'s will correlate with this or not, but it may be that one has a longer wiring lead...just a guess



    [

  8. #38
    apriliaforum Member Uriel's Avatar
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    Great thread Joe! That website of yours if rather handy too. Will be checking mine in a couple of weeks. Sounds like they are loose and arcing, that would explain the high resistance and overheating as the current demand increases.

  9. #39
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    Mine appears to have 1 connector and my serial number ends 2462.

  10. #40
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    Quote Originally Posted by argentifa View Post
    slightly confused here chaps...the three yellows running out of the alternator....

    are they in principle the same as a 3 phase?

    i.e. ...it doesn't matter which one is whch....so in theory, they can't be connected the wrong way around...?
    ....so...the yellows....are they all the same..?

  11. #41
    apriliaforum Member Joe250's Avatar
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    Quote Originally Posted by argentifa View Post
    ....so...the yellows....are they all the same..?
    Please see post #18.

  12. #42
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    Quote Originally Posted by Joe250 View Post
    Please see post #18.
    ahaaaaaaa.....I see....

    thanks for that Joe....


    *goes and dusts off wire cutters & crimping tool...*

  13. #43
    apriliaforum Junkie putz's Avatar
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    Not one mention of repair under warranty?!
    I been down, but I aint out!

  14. #44
    apriliaforum expert TUONOAPE's Avatar
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    Quote Originally Posted by putz View Post
    Not one mention of repair under warranty?!
    they'd probably repair it to factory spec - and then your still in the same situation

    Maybe it should be a recall?
    "I have had mostly Ducatiís for over 10 years... thank goodness I found the Aprilia!" (Sinex 2008)
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  15. #45
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    Quote Originally Posted by TUONOAPE View Post
    Maybe it should be a recall?
    only if the connector was close to the fuel supply I recon..

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