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C

carbon kid

Guest
so there I was back at the garage again after getting bike serviced and booted. had a look at the integrated rear light unit that was ordered and the bugger wouldnt fit. Mighty glad we took the seat unit off cos I found the brown multiconnector to the reg was completely melted into a brown blob:eek:
Soon changed them ..but two days before our mototgp trip, could have well been stranded(poo).
Least its fixed. Dont know how it =ot soooo hot to melt like that into a pile of poo.
Ck
 
carbon kid said:
so there I was back at the garage again after getting bike serviced and booted. had a look at the integrated rear light unit that was ordered and the bugger wouldnt fit. Mighty glad we took the seat unit off cos I found the brown multiconnector to the reg was completely melted into a brown blob:eek:
Soon changed them ..but two days before our mototgp trip, could have well been stranded(poo).
Least its fixed. Dont know how it =ot soooo hot to melt like that into a pile of poo.
Ck
Click to expand...

Its a know fault, as the brown connectors offer resistance in the circuit, and therefore become very hot. I did both of mine 2 weeks ago as a precaution.
 
I thought that the brown connector problem was common on the new shape but not in the old one. I have noticed some black spots that look like have been cause by sparks near the brown connector on the subframe. I can see them when I take the pillion seat off. I haven't worried as the bike runs well and it reads 13,3V at tickover with the lights on. Has anyone have this happening to his bike?
 
:thumbup:worthless
Good find CK, always drama before a trip, got my tail unit off at min doing my rear lights, what does this connector look like/ go to ?
 
i have the 07 model, are the brown connector gremlins a problem for me? what's the solution or should i wait to see if they start burning up?
 
St. if yer sat on the bike the connector is a brown multi type jobbie jst under the rt side of seat unit beside subframe, there is a white on ethere also.
Danf, when you said you chnaged both do you mean the white one too, on the same side?
cheers Ck
PS_no pix needed just take a look at a the next pile of poo you see on the pavement.
Just glad its sorted in time.
See you all after the mototgp!!
 
supertedlover said:
:thumbup:worthless
Good find CK, always drama before a trip, got my tail unit off at min doing my rear lights, what does this connector look like/ go to ?
Click to expand...


ST mate ,where did you order the light unit from??, the one my garage got from Bikeit was completely wrong size(fools)
 
The brown connector on the 04 onwards bikes that causes the main issue is different to the one mentioned earlier. From 06 it was removed anyway leaving 1 at the rectifier.

To be honest any connector in the charge circuit is capable of melting if it develops high resistance because of the high current involved.. Rectifier plugs are much less of a problem than the between cylinder jobby that causes such problems on 04/05 bikes.

There is a white connector under the seat unit that i've seen melt as well.
 
does anyone have any ideas as to why there is such a big problem with resistance in connections. i worked in the motor trade for 5 years and never came across anything like this, and i have never heard any other bike manufacturer having a problem. is it based on metallurgy, or poor build quality.:dunno
spoonz i know it is a lot to ask, but bearing in mind that you appear to be one of the more knowledgeable guys on here with respect to this kind of thing, would it be possible for you to correlate a list of connections which cause problems and should be checked for each of the years. and describe where to find these connections and what to do with them.:thumbup
It may well be worth putting something together in the how to part of the forum.
 
can do.

The connectors are not Aprilia exclusive and are certainly manufacturer specced as man enough.
The problem seems to partly stem from the crimping process onto the spade connector in the plugs. When that is 100% all is fine but with vibration etc the connection can become less than perfect.

Part of the problem also comes from the design of the charging circuit which In effect produces max power 100% of the time and the regulator just dumps what it doesn't need to ground. That means the wiring and rectifier/regulator get very hot which doesn't help.
 
got it from www.superbike-center.co.uk, blokes name is Steve, he is sound, will do a thread when all is done, had to go out last night so only 1/2 way through job. Initial thoughts are it looks the dogs danglies and no flaher relay requires. result.

Heroblob, am still in motor trade, over 10yr now and agree none of this happens on cars
 
Is it possible to change the charging system to something more conventional. what would be required, new reg/rect, or new alternator/stator unit, both, or can't it be done.
thoughts on a post card. or here will do.
oh and thanks spoonz for offering to do the list of checks and mods. may stop a huge number of future problems for people.
 
Not really practical or cost effective unless you need to replace the stator anyway.

If my stator failed i would not buy the aprilia part partly because of cost but mostly because i would have my old one rewound with thicker gauge windings and also thicker gauge wire to the rectifier. The less resitance the better and more load/heat it will take.

You could go to a series regulator that clips the stator output phases at source rather than it producing 100% all the time and then shunting the excess.

Generally i would say keep an eye on your connectors and consider the other options as and when the worst happens.
 
Post a pic where to find this wire and dodgy connections pls
 
heroblob said:
Is it possible to change the charging system to something more conventional. what would be required, new reg/rect, or new alternator/stator unit, both, or can't it be done.
thoughts on a post card. or here will do.
oh and thanks spoonz for offering to do the list of checks and mods. may stop a huge number of future problems for people.
Click to expand...

Have a chat to these guys CLICKY for a long term cure. As SPOONZ said, the charging system is not the best and i went for prevention rather than cure because you cant bump start a v twin easy and it's a big heavy bike to push :lol
 
Ok i'll try and cover the coomon failures with pics.

All models of rotax twin have a brown connector at the rectifier which needs watching for melting. On right side of bike behind faring. This pic is a Futura version.

3.jpg



There is also a white connector near the rectifier which melts less often but also worth watching. (not on later models)

connector.JPG


Connector in tail

PICT1399%2520%255B400x400%255D.JPG


PICT2239%2520%255B400x400%255D.JPG


Lastly for 04-06 Rsv's the brown connector behind the rad expansion tank right hand side. If it's melted cut off the connector and pull back through to left side and run up left frame rail and over the rad and solder and crimp with new connectors.

fried%2520%2528Custom%2529.jpg
 

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