[OreoGitorio]

lately the charging system has been weak on the Tuono... there's a known issue with the rectifier/regulator & a brown connector that's used to connect it to the wiring harness... but when I removed the tail section to inspect it, it seemed alright & the battery is getting 13-14 volts at idle & 4000rpm.

Out of curiosity, before I removed the brown connector & rewired the rec/red I decided to check another connector that sits under the gas tank near the rear cylinder head that some people have reported issues with... um.. yeah, that don't look quite right.

http://www.apriliaforum.com/forums/a...1&d=1206215093

http://www.apriliaforum.com/forums/a...1&d=1206214987

http://www.apriliaforum.com/forums/a...1&d=1206217121


I think the solution lies in cutting out that connector & replacing the connector with 5 individual 30 amp connectors. A couple other guys on apriliaforum.com have done this with positive results so I'm gonna seek their advice & get this potential fire hazard outta there. I wanna be able to run my heated grips, heated vest & radar detector with the piece of mind that the bike isn't gonna shit the bed or catch fire.

This is virtually the ONLY common problem that people report with this bike. Otherwise it's as reliable as a frikkin Honda.

[jmh992003]

your assumption is right... it doesnt look right. Whast do they say causes this? The whole thing just looks over heated.

[LuvDog]

Yup.. typical Italian engineering. Older ducs have the same issue. Too much resistance in the connectors and the wiring.

You're on the right track... replace that with better connectors is a good start. If you have the time... replace that wiring with a heavier gauge too.

[Ryno]

Had to do something similar on my Brother's 916

[burnham]

The connectors get loose over time, if you catch it early you can pack them with dielectric (sp) grease. I cut mine out after they failed and soldiered them. The wiring is sized correctly, no need to go bigger.

[CMG241]

Originally Posted by LuvDog

Yup.. typical Italian engineering. Older ducs have the same issue. Too much resistance in the connectors and the wiring.

You're on the right track... replace that with better connectors is a good start. If you have the time... replace that wiring with a heavier gauge too.

and how about old Fiats!

[schleppy]

You don't think there is any way to get a new spade connector in there (that's what it looks like it is)? I'm sure if you brought pictures to a place like you-do-it electronics they could source those. Then you could clean up the connector, douche it in dialelectric grease, and give it a go.

Lopping off that connector entirely seems like a risky/potentially problematic move.