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Thread: Gabro's IGen Tuning Kit (collector mod + airkit): almost ready

  1. #1
    apriliaforum expert Gabro's Avatar
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    Gabro's IGen Tuning Kit (collector mod + airkit): almost ready

    Last week i did i big dyno-work to develop Eproms to be used with my "tuning kits". Will start to sell 'em soon.

    Kits will be composed by:
    1- a modified collector with 2 cross-pipes, studied to give the best overall performance, liming the losses below 4000rpm and the flat top end that some of other makers collector gives.
    2- an airkit, with a free flow airfilter and a gasket ring for using the tank as the real airbox top lid.

    I've used a very mint '03 RSV-R as test mule, and collected total 5 days at the test bay, doing 350km on the roller, burning 25lt of fuel in order to test a lot of combinations of headers, can, throttle bodyes, intake staks, airbox lid.

    Dyno sessions has been held using 2 wideband lambda installed in both fron and rear header. Datalogs has been used to build the EPROM correct fueling.

    All the graph below are showing rearwheel power and torque, expressed in CV(PS) and Nm.
    Luckily last week had a stable weather and bike has been tied down to the dyno from start to finish, i've been very care to runs repatibility so graph comparation should be pretty accurate.

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    Last edited by Gabro; 09-28-2015 at 01:58 PM.
    Aprilia bikes ECU tuning and reflashes since 2004!
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  2. #2
    apriliaforum expert Gabro's Avatar
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    For the tests, i've used 4 different end cans:
    0- stock bronze "boiler" can, de-restricted.
    1- Arrow
    2- Titanium (small end)
    3- shortened Titanium

    Here the base runs, were the full de-restricted stock bike with the "boiler" (air intake and exhaust restrictors removed, european eprom, so it has the secondary map accessed by cutting PIN16) is compared with the 3 open aftermarket cans with Ti eprom. Bike run very good at WOT with the stock can! All 3 aftermarket cans graph shows the dip in torque @5500rpm were the stock can does not.
    Anyway, full power pulls does not tells the whole story... part throttle is much more strong on open cans than stock boiler.

    Arrow Can + eprom VS stock derestricted bike:

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    Titanium can + eprom VS stock derestricted bike:

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    Shortened Titanium can + eprom VS stock derestricted bike:

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    Last edited by Gabro; 09-28-2015 at 02:20 PM.
    Aprilia bikes ECU tuning and reflashes since 2004!
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  3. #3
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    Gab, I'm very much looking forward to seeing the output graphs.

    By the way - kudos for emphasis on proper welding of the crossovers. I've personally witnessed hack-yard cobble-ups where a torch was used to blow a hole into headers at the crossover unions which were obviously unseen once the crossovers were welded in place . The transition ports must very closely match the connector tubes in order to fully realize the benefits of this modification. Not all too long ago on eBay, I purchased and actually cut open a modified header only to discover an inefficient jagged, ugly, hole when I was chasing down less than satisfactory performance. Our machines are high quality Italian jewels - anything less than the attention to detail exhibited by the rest of the platform is not an enhancement but a detriment.

    Several years ago I discussed this very issue with Kiddo before his untimely passing, who also corroborated the importance of this detail as odd running glitches surfaced unless proper orifice matching was carried out.

    This is how the header should be prepared for the modification which I'm relatively certain - you have done.

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    -doc
    Last edited by BMEPdoc; 09-28-2015 at 10:00 AM.

  4. #4
    apriliaforum expert Gabro's Avatar
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    Yes! My welder is a true artist!
    we kept the holes a little smaller than crossover ID by 2mm, but holes are perfectly shaped.
    we moved the main U crossover in various positions prior to find a good placement that gives the best overall performances.

    i'm now updating the previous posts of the thread with pisc and dyno graph.
    Aprilia bikes ECU tuning and reflashes since 2004!
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  5. #5
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    Did you also use different TB sizes?

  6. #6
    apriliaforum expert Gabro's Avatar
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    Quote Originally Posted by mona-toetje View Post
    Did you also use different TB sizes?
    yes, i've used both stock 51mm and IIGen 57's. Report will follow
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  7. #7
    apriliaforum expert redratbike's Avatar
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    35mm internal diameter pipe ????

  8. #8
    apriliaforum expert Gabro's Avatar
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    So... after base runs, i've installed the modified collector, and mapped it using the Arrow. Arrow and Ti can have simiar fuel needings and performance, so i've limited the test to the Arrow and the shortened Ti can only.

    here the results using the modified collector and the Arrow, with custom eprom, Vs stock headers and Arrow can + eprom:

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    here below the results using modified collector and the Ti-shorty, with the same previous eprom, Vs stock de-restriced bike. The shorty perform very good in the low rpm region and in the upper revs, but still shows the 5500rpm dip in torque with the modified headers too... it's now very limited, but still present

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  9. #9
    apriliaforum expert Gabro's Avatar
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    I've re-tested the Boiler on modified collectors. here the results, using the eprom developed for the headers+arrow VS the graph from the full stock de-restricted bike condition.
    it shows a loss in torque below 4000rpm, but a very good improvement in any other zone. not bad for just a modified header and a generic eprom installed in a full stock bike, including the can!

    Click image for larger version. 

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  10. #10
    apriliaforum expert Gabro's Avatar
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    than, was time to test the airkit!

    i've installed it (airbox seal ring and sponge airfilter) and re-did the previous test, running modified collector, eprom and stock boiler can.
    Here below the net gain of the airkit only... motor is a bit softner (again) below 4000rpm, but give 2-3HPs more above:

    Click image for larger version. 

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  11. #11
    apriliaforum expert Gabro's Avatar
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    Here the net gain (and losses, below 4000rpm) of my parts (modified headers, airkit and matching eprom) installed in a full stock bike with Boiler can:

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  12. #12
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    This is some very nice work. And very usefull. Will be interested in the 57mm graphs. Will the eprom be much different from the old eprom you build for the 57mm?

  13. #13
    apriliaforum expert Gabro's Avatar
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    the airkit works even better running with modified collectors and Arrow can:

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    Here the gains, running the Arrow can, of the modified header + airkit VS stock header and stock airbox:

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  14. #14
    apriliaforum expert Gabro's Avatar
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    Things are starting to become intresting, uh?! Tomorrow i'll go ahead with the 57mm TB's test

    Quote Originally Posted by mona-toetje View Post
    This is some very nice work. And very usefull. Will be interested in the 57mm graphs. Will the eprom be much different from the old eprom you build for the 57mm?
    not much. i still continue to sell the old eproms for generic application. But those new eprom are developed to work specifically with my version of modded collector so they can be a bit more refined.
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  15. #15
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    Looks great. Looking to see what the prices will be USD. Great job.

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