Recall 16V691 affects 1,628 2014-2016 Aprilia Tuono and Caponord motorcycles for a front brake master cylinder defect. Repair is free at any franchised Aprilia dealer.
Aprilia is recalling 1,628 2014-2016 Caponord Rally, Tuono V4 1100, Tuono V4 1000, and Caponord 1200 motorcycles because the front brake master cylinder can let air into the hydraulic circuit. Longer braking distance increases crash risk, and Aprilia dealers will complete the recall repair free of charge.
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What's wrong?
On the 2014-2016 Aprilia Caponord Rally, Tuono V4 1100, Tuono V4 1000, and Caponord 1200 motorcycles in this recall, the front brake master cylinder is the hand-control part that starts front braking. When you squeeze the brake lever, the master cylinder pressurizes brake fluid and sends that pressure through the hydraulic circuit to the front brake calipers. The system depends on sealed fluid pressure.
The recall concerns internal brake pump parts, the actuating rod and cap, that do not seal the hydraulic circuit as intended. The older design uses a push pin and rubber cap as separate pieces, while the replacement part uses a one-piece push pin and rubber cap with a revised actuating rod profile. When air enters the hydraulic circuit, the brake lever loses some of its normal pressure transfer.
The warning sign is longer than normal braking distance. If the motorcycle takes more room to stop than usual, the front brake system is not building pressure the way it should.
Who's affected?
Spans 4 Aprilia models across the 2014-2016 model years, all tied to the hydraulic brake system.
| 2016 Aprilia Caponord Rally | hydraulic brake system |
|---|---|
| 2016 Aprilia Tuono V4 1100 | hydraulic brake system |
| 2014 Aprilia Tuono V4 1000 | hydraulic brake system |
| 2015 Aprilia Tuono V4 1000 | hydraulic brake system |
| 2015 Aprilia Caponord 1200 | hydraulic brake system |
| Units affected | 1,628 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching model year and model does not guarantee inclusion. Check your VIN to confirm whether your specific motorcycle is included.
What's the safety risk?
Longer than normal braking distance means the motorcycle needs more room to stop and increases the risk of a crash. Treat abnormal braking as a reason to stop riding and call an Aprilia dealer. Repair is free at any franchised Aprilia dealer.
What should I do?
- Check your VIN to confirm your 2014-2016 Aprilia Caponord Rally, Tuono V4 1100, Tuono V4 1000, or Caponord 1200 is included in this recall.
- Contact a franchised Aprilia dealer to schedule the free front brake master cylinder pushrod and boot assembly replacement that keeps air out of the hydraulic circuit.
- Bring the recall notice if Aprilia mailed one. If not, reference recall number 16V691 when you call.
- Ride cautiously until the repair is complete. Leave extra stopping distance and avoid hard braking.
- Call Aprilia customer service at 1-866-705-1727 with questions about the recall or dealer scheduling.
What happens at the repair
At the dealer, an Aprilia technician replaces the front brake master cylinder pushrod and boot assembly. The repair addresses the master cylinder condition that can let air into the hydraulic circuit and increase braking distance. The recall repair is free, including parts and labor. If your motorcycle is included, schedule the recall work with an Aprilia dealer and ask the service desk whether any brake-related inspection is needed before you ride it in.
Timeline
| September 22, 2016 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
|---|---|
| September 26, 2016 | NHTSA published the recall |
| September 27, 2016 | Owner notification mailed |
| September 27, 2016 | Dealer notification began |
| September 30, 2016 | Dealer notification ended |
| September 30, 2016 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 16V691?
Recall 16V691 covers 1,628 2014-2016 Aprilia Caponord Rally, Tuono V4 1100, Tuono V4 1000, and Caponord 1200 motorcycles with a front brake master cylinder defect. Air can enter the hydraulic circuit, causing longer stopping distance. Aprilia dealers replace the front brake master cylinder pushrod and boot assembly for free.
What should I do if my 2014-2016 Aprilia motorcycle is on this recall?
Check your VIN to confirm your specific motorcycle is included in recall 16V691. If it is, contact a franchised Aprilia dealer to schedule replacement of the front brake master cylinder pushrod and boot assembly. Reference recall number 16V691 when you call. The repair is free.
Is the Aprilia recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. Aprilia dealers will replace the front brake master cylinder pushrod and boot assembly free of charge, regardless of where you bought the motorcycle.
What is the safety risk in recall 16V691?
The safety risk is longer stopping distance. The affected front brake master cylinder can let air enter the hydraulic circuit, so the motorcycle requires an abnormal distance to stop. Aprilia's filing states that this increases crash risk, and the dealer repair addresses the brake master cylinder parts for free.
What if I bought my Aprilia motorcycle used?
The free recall repair still applies. Federal recall law follows the vehicle, not the first owner. Check your VIN to confirm whether your specific Aprilia motorcycle is included, then call a franchised Aprilia dealer or Aprilia customer service at 1-866-705-1727 with recall number 16V691.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/16V691000 |
|---|---|
| Aprilia customer service | 1-866-705-1727 |
| NHTSA recall # | 16V691 |
| NHTSA recall # (full) | 16V691000 |
Source documents
-
Download Owner Notice (PDF) - Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →