Finding the right aprilia tuono 660 exhaust is probably the first thing on your mind after you realize how choked up the stock system sounds compared to what this bike is actually capable of. Don't get me wrong, the Tuono 660 is a fantastic piece of machinery—it's light, flickable, and has that Italian soul we all crave—but that massive "lunchbox" underneath the engine isn't doing the 270-degree parallel twin any favors.
When you pick up a Tuono, you're basically getting a mini-RSV4 experience in a more comfortable package. But while the RSV4 screams like a MotoGP bike, the stock 660 purrs a bit too politely. If you want that deep, rhythmic thumping that makes people turn their heads at a stoplight, an exhaust swap is pretty much mandatory.
Why Even Bother Replacing the Stock Pipe?
The most obvious reason is the sound. Because of the 270-degree crank, the 660 engine mimics the firing order of a V-twin (or half a V4). It has this syncopated, growly character that sounds incredible when it's allowed to breathe. The stock aprilia tuono 660 exhaust is built to satisfy Euro 5 emissions standards, which means it's packed with catalysts and baffles that kill the personality of the bike.
Beyond the noise, there's a massive weight difference. The stock system is a heavy, one-piece unit that sits low and adds quite a bit of bulk. Switching to a high-quality aftermarket system can shave off anywhere from 5 to 10 pounds. On a bike this light, you actually feel that difference when you're transitioning through corners.
Then there's the looks. The stock underbelly exhaust is "fine," but it's a bit industrial. Whether you want a shorty canister that stays tucked away or a high-mount pipe that screams "race bike," the aftermarket has you covered.
Full System vs. Slip-on: The Big Distinction
Here's the thing with the Tuono 660: you can't just buy a "slip-on" in the traditional sense. On many bikes, you can just swap the muffler and keep the headers. But with the aprilia tuono 660 exhaust design, the muffler and the headers are often welded or integrated in a way that requires a full system if you want to see real gains.
Most of the popular options you'll see from brands like Akrapovič, SC-Project, or MIVV are full systems. They replace everything from the engine ports to the tip. This is why they're a bit more expensive than what you might be used to, but it also means the performance gains are more consistent because the entire airflow path is optimized.
The Big Players: Which Brand Should You Choose?
Akrapovič: The "Official" Choice
If you walk into an Aprilia dealership, they're going to point you toward Akrapovič. They have a long-standing partnership with the brand. The "race" version of the Akrapovič system is beautiful, made of high-quality titanium, and usually comes with a map that keeps your warranty intact if installed by a dealer. It's not the loudest system out there, but it's arguably the most "refined." It sounds sophisticated and growly without being obnoxious.
SC-Project: For the Rowdy Crowd
If you want your neighbors to know exactly when you're leaving for work, SC-Project is the way to go. Their SC1-R or the S1 systems are legendary for being loud and aggressive. They look incredibly sharp and give the Tuono a raw, mechanical edge. It turns that 660 into a bike that sounds twice its size. Just be prepared; it's a "loud pipes save lives" kind of vibe.
MIVV: The Budget-Friendly Powerhouse
MIVV offers some of the best bang-for-your-buck options. Their Delta Race or low-mount systems look great and provide a significant sound upgrade without costing as much as a used scooter. They have a slightly more "hollow" growl compared to the Akra, but it's still miles better than the stock sewing machine sound.
Spark: The Italian Style
Spark is an Italian brand that just fits the aesthetic of the Tuono. Their systems are often very compact and offer a unique look that sets your bike apart from the sea of Akrapovič stickers. They put a lot of work into the resonance of the pipe, giving it a very "clean" tone even at high RPMs.
Do You Need a Tune?
This is the question that haunts every forum. If you change your aprilia tuono 660 exhaust to a full system, do you need to remap the ECU? The short answer is: you really should.
When you remove the catalytic converter and open up the airflow, the bike starts running lean. Modern Euro 5 bikes are already tuned to run lean from the factory to save on emissions. Adding a high-flow exhaust makes it even worse. You might notice "popping" on deceleration, a "flat spot" in the midrange, or the bike running hotter than usual.
Most people go with the UpMap T800+. It's a little device that plugs into your diagnostic port and lets you flash a new map using your phone. It's a game-changer. It smooths out the throttle response and makes sure your engine isn't slowly cooking itself. Plus, it usually adds a few extra ponies at the top end.
Installation: A DIY Job or a Shop Visit?
Changing the exhaust on the Tuono 660 isn't the hardest job in the world, but it's not a five-minute task either. You have to remove the lower fairings (the "belly pan"), which can be a bit fiddly. Getting the headers to seat correctly against the engine block requires a bit of patience and maybe an extra set of hands.
If you're comfortable with a wrench and have a decent set of sockets, you can do it in an afternoon. Just remember to get new copper gaskets for the headers. Reusing the old ones is a recipe for an exhaust leak, which sounds like a clicking noise and drives you crazy once you notice it.
Living with an Aftermarket Exhaust
There's a honeymoon phase where you'll want to rev the bike everywhere just to hear it. But after a few weeks, you'll realize a couple of things. First, the heat management changes. Some aftermarket pipes run cooler because they don't have a massive catalytic converter holding onto heat right under your feet.
Second, ground clearance. Some low-mount systems can be a bit tucked out, so if you're a track day junkie or you like to lean the bike over until the pegs scrape, check the clearance of the pipe you're buying.
Lastly, consider the "baffle in" vs. "baffle out" life. Most systems come with a removable dB killer. Keeping it in makes the bike much more tolerable for long tours. Taking it out is great for the track or short weekend blasts, but it can get tiring on a three-hour highway stretch.
Final Thoughts
At the end of the day, an aprilia tuono 660 exhaust upgrade is about making the bike feel like yours. The Tuono 660 is a masterpiece of middleweight engineering, but it's a masterpiece that's been muffled by regulations.
Whether you go for the premium Akrapovič, the aggressive SC-Project, or the stylish Spark, you're going to enjoy the bike 100% more once you can actually hear that engine singing. Just do yourself a favor: get the tune, save your stock parts in a box in the garage, and go enjoy that Italian triple-like growl. It's what the bike was meant to do.