Swapping out your stock tuono 660 exhaust is probably the first thing you'll want to do after the break-in period is over. Let's be honest—Aprilia built an absolute gem of a middleweight naked bike, but thanks to strict Euro 5 emissions standards, the factory exhaust sounds a bit like a sewing machine. That 270-degree crank is designed to mimic the soul and character of a V4, but you really can't hear that personality until you ditch the massive, heavy breadbox living under the engine.
If you're looking to shave some weight, clean up the bike's silhouette, and finally hear that parallel-twin growl, you've got a lot of choices. But picking the right one isn't just about finding the loudest pipe on the shelf. It's about finding that balance between performance, aesthetics, and not annoying your neighbors too much—unless that's your goal, of course.
Why the Stock Setup Has to Go
The factory exhaust on the Tuono 660 is a feat of engineering, but not necessarily the kind we like. It's designed to keep the bike quiet and the air clean, which means it's packed with catalysts and baffles that weigh a ton. Seriously, when you finally pull the stock system off, you'll be shocked at how heavy that "belly pan" actually is.
Aside from the weight, the stock tuono 660 exhaust hides the bike's natural rhythm. That 660cc engine has a firing order that makes it sound incredibly aggressive once it's allowed to breathe. Replacing it doesn't just change the volume; it changes the entire riding experience. You get more feedback from the engine, and the bike feels a lot more alive when you're clicking through the quickshifter.
The Full System vs. Slip-On Debate
Here's the tricky part about the Tuono 660: it doesn't really do "slip-ons" in the traditional sense. On many bikes, you can just pop off the muffler and slide a new one on. Because the Tuono 660's exhaust is a one-piece underslung unit, most of the aftermarket options are full systems.
This means you're replacing everything from the headers back. It's a bigger job and a bigger investment, but the payoff is much higher. You get a significant weight reduction and a much smoother flow of exhaust gases. Some companies offer a "half-system" that cuts into the stock headers, but honestly, if you're going to the trouble of taking the fairings off, you might as well go all the way with a full system.
Top Brands to Keep on Your Radar
When you start shopping for a tuono 660 exhaust, a few names are going to keep popping up. Each one has a slightly different "flavor" in terms of sound and style.
SC Project: The Racing Vibe
If you want your Tuono to sound like a Moto2 bike, SC Project is usually the go-to. Their systems, like the S1 or the SC1-R, are unapologetically loud and incredibly light. They have a very raw, metallic scream at high RPMs. They look fantastic, too—usually featuring high-quality titanium and carbon fiber tips. Just be warned: these are loud. If you live in an area with strict noise enforcement, you might want to look at their versions that include a baffle.
Akrapovic: The Factory Choice
Aprilia and Akrapovic have a long-standing relationship. If you go into an Aprilia dealership, this is likely what they'll recommend. The Akrapovic tuono 660 exhaust is often considered the "gold standard" for fit and finish. It's a bit more refined than the SC Project. It has a deep, bassy tone that sounds expensive. It's also one of the few brands that offers a street-legal, Euro 5-compliant carbon system that still sounds way better than stock without being obnoxious.
Mivv: The Balanced Option
Mivv is a great choice if you want high quality without the "Akra-tax" price tag. Their Delta Race and X-M5 systems look very modern and fit the Tuono's aggressive styling perfectly. They tend to offer a nice middle ground—a bit louder and "meaner" than the street Akrapovic, but a little more manageable for daily riding than a full-blown race pipe.
Spark: Italian Style
Spark is another Italian brand that makes a stunning system for the 660. Their Grid-O silencer is one of the coolest-looking pipes on the market. It's tiny, aggressive, and has a very unique honeycomb mesh on the outlet. It's definitely for the rider who wants their bike to stand out at the local bike meet.
Performance Gains and the Need for a Map
Let's talk about the elephant in the room: fueling. If you install a high-flow tuono 660 exhaust, you are changing how air moves through the engine. If you don't adjust the fueling, the bike will likely run "lean" (too much air, not enough fuel). This can cause the engine to run hot, pop excessively on deceleration, or even have "flat spots" in the powerband.
Most riders in the Aprilia community swear by the UpMap T800+. It's a little device that plugs into your bike's diagnostic port and allows you to flash a new engine map specifically designed for your new exhaust. Using a dedicated map from someone like Gabro Racing doesn't just prevent engine damage; it actually unlocks the power you're looking for. You can expect a smoother throttle response and a nice little bump in horsepower and torque across the rev range.
What It's Like to Live With an Aftermarket Pipe
Installing a new tuono 660 exhaust definitely changes the bike's personality. On the highway, you'll notice the bike feels a bit more "eager." The weight savings—usually around 3 to 4 kilograms—doesn't sound like much on paper, but you can feel it when transitioning the bike through tight S-turns. It feels just a little more flickable.
The sound, however, is the biggest change. At idle, you get a lovely low-end thrum. When you're cruising at 5,000 RPM, it's a steady, purposeful drone. But when you pin the throttle and hit that 10,000 RPM redline, it's absolute music. The downshifts with the quickshifter become addictive because of the little barks and pops you get from the exhaust.
One thing to consider is "drone." If you do a lot of long-distance touring, an extremely loud pipe might get tiring after four hours in the saddle. That's where the "street" versions of these exhausts come in handy. They usually have a removable dB killer, giving you the option to keep it civil for the commute and open it up for the track or weekend canyon runs.
Installation: Can You Do It Yourself?
If you're handy with a wrench, you can definitely install a tuono 660 exhaust in your garage. However, it's a bit more involved than a simple muffler swap. You'll need to remove the lower fairings and the chin spoiler. Accessing the header bolts can be a little tight, and you'll want to be careful not to scratch the frame or the radiator fins.
It's a good idea to have a set of fresh exhaust gaskets on hand, even if the bike is relatively new. It's also worth noting that once you install the new system, you should wipe down the pipes with rubbing alcohol before starting the bike for the first time. Any fingerprints or oils left on the metal will "bake" into the finish as soon as the pipes get hot, leaving permanent marks.
Final Thoughts
At the end of the day, a tuono 660 exhaust is probably the best investment you can make for this bike. It fixes the only real complaint most people have about the Tuono—that it sounds a bit too polite. Whether you go for the premium finish of an Akrapovic, the raw aggression of an SC Project, or the stylish Italian flair of a Spark system, you're going to end up with a bike that looks better, handles better, and sounds exactly like a mid-sized Italian sportbike should. Just don't forget the ECU map—your engine will thank you for it, and the extra power is a nice cherry on top.