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Thread: OpenFlash Stage 3 Development

  1. #1
    apriliaforum Member
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    Smile OpenFlash Stage 3 Development-- MORE POWER

    Hi Guys,
    A couple months ago, with the assistance of Ed at AF1, I started testing intake upgrades on my personal 2017 Tuono. After testing many different configurations, I finally settled on a set-up that works very well. I am using an airbox from a 2017 RSV4 along with special assortment of velocity stacks. It took some time to find the optimal stack set-up but I'm happy we stuck with it. I know other tuners have claimed to have had little success with using an RSV4 airbox/stacks but I can only speak for the results we have achieved. Granted, I put a lot of time into this project. But I tend to spent a lot of time tweaking my personal bikes. Doing this kind of development on a customer bike wouldn't have been feasible.

    First, let's look at the difference between the 2107 Tuono and 2017 RSV4 airboxes (without stacks installed):


    The RSV4 intake has a much larger panel filter. It's also made from a less restrictive material. it sits more upright and is fed by larger and smoother twin air ducts:



    The top half of the RSV4 airbox (not shown) also has cutouts for the secondary injectors. I plugged them up for this application since the Tuono doesn't have secondary injectors.

    The Tuono also uses very tall velocity stacks which is typical of an engine that is tuned for more low end torque at the expense of top end power:


    By comparisons, here is the setup we ended up with:


    When I first started doing pulls on the dyno, I were pleasantly surprised by what I saw. There was some minor torque loss in the midrange. And AFR above 7k rpm would lean out noticeably. More so on the front cylinders which run a shorter stack then the rear. This suggests that the engine is breathing better up up. So I tinkered with some torque table, adjusted fuel mapping per cylinder and played around with injection timing. After 40+ dyno pulls everything fell into place nicely. I was able to minimize the midrange torque loss while making some very nice gains up top:

    BLUE: Akrapovic Evo exhaust and OpenFlash Tablet (Stage 2 tune)
    RED: Akrapovic Evo exhaust, RSV4 induction kit and OpenFlash Tablet (Stage 3 tune)

    Comparing peak power numbers, you see a healthy 5hp gain. But maximum gains of 13hp are found at 12.5k RPM. When tuning usually involves fighting for 1-2hp gain, seeing a 13hp gain is HUGE. On the road, the re-shaping of the power curve makes the Tuono feel very rev happy. It charges to redline and feels more linear (because it is).

    To get a better perspective on the power gains the OFT Stage 3 tune and RSV4 induction kit provide:

    BLUE: Akrapovic Evo exhaust and Aprilia Race ECU tune
    RED: Akrapovic Evo exhaust, RSV4 induction kit and OpenFlash Tablet (Stage 3 tune)

    No torque loss anywhere and huge power gains above 8000rpm. 22HP gains at 12k RPM.

    Here is also an interesting comparisons with other bikes also tested on this same dyno:

    PINK: Stock 2016 RSV4 RF
    BLUE: 2017 RSV4 RF with Akrapovic slip-on and Race ECU
    RED: 2017 Tuono Factory with Akrapovic Evo exhaust, RSV4 induction kit and OpenFlash Tablet (Stage 3 tune)

    What's next?
    I still have a few things I'd like to test on the dyno before releasing this tune. Ed@AF1 and I also need to sort out all the parts necessary for a actual production RSV4 induction kit. I think there is a few more HP left in the set-up. I ran out of time today so I had to cut my dyno tuning session a little short. I'll get back on the next few days to wrap things up. Of course, I'll post updated dyno results as they come in.
    Last edited by OpenFlash; 02-06-2018 at 01:06 AM.
    In the Garage:
    2019 RSV4 1100 Factory
    2018 Panigale V4 S
    2017 Tuono Factory
    2017 Yamaha R6
    2011 Ferrari 458
    2019 BMW M2 Competition
    2016 AMG GT S
    2016 Mazda CX5
    2017 Charger Hellcat
    2017 Toyota Tacoma
    OpenFlash Tablet
    Free Tunes || 3-Touch Programming || Digital Gauge Displays || Datalogging || Handheld Convenience || No Laptop Required

  2. #2
    apriliaforum Member HotRod104's Avatar
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    All sounds very good! I do have a question about if you have based this of of the latest update maps from Aprilia, the _20?

  3. #3
    apriliaforum Member
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    Quote Originally Posted by HotRod104 View Post
    All sounds very good! I do have a question about if you have based this of of the latest update maps from Aprilia, the _20?
    Yes, it is based on the newest Race ECU calibration (7614LD20).
    In the Garage:
    2019 RSV4 1100 Factory
    2018 Panigale V4 S
    2017 Tuono Factory
    2017 Yamaha R6
    2011 Ferrari 458
    2019 BMW M2 Competition
    2016 AMG GT S
    2016 Mazda CX5
    2017 Charger Hellcat
    2017 Toyota Tacoma
    OpenFlash Tablet
    Free Tunes || 3-Touch Programming || Digital Gauge Displays || Datalogging || Handheld Convenience || No Laptop Required

  4. #4
    apriliaforum prov-nov
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    Will any of this work on a 16?

    Sent from my SAMSUNG-SM-G935A using Tapatalk

  5. #5
    apriliaforum expert
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    Do any of the tunes you offer raise the rev limiter?

    -- Randy
    2011 RSV4 FACTORY SE
    2003 CBR600RR - TRACK BIKE

  6. #6
    apriliaforum expert cmutza's Avatar
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    This is awesome! Really looking forward to when you have time to try this setup on a pre-2016 RSV4 too!

  7. #7
    apriliaforum expert vfr1200's Avatar
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    Fantastic; what is the conversion number for mph to rpm?
    So stage 2 is for slip on, and stage 3 is for slip on + RSV intake?
    And are the 2017/2018 Tuono maps the same as my 2016 Tuono?
    Is there any loss to having the butterfly in the 2016 stock exhaust vs. the full akra system?
    Would you recommend a stock RSV air filter or an aftermarket like DNA?
    great work.
    2017 Sherco 300 SER Factory
    2016 Tuono 1100 Factory
    2015 TREK 7.3
    https://www.amazon.com/s/ref=nb_sb_n...alan+golightly

  8. #8
    apriliaforum Member
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    Quote Originally Posted by CBinks View Post
    Will any of this work on a 16?

    Sent from my SAMSUNG-SM-G935A using Tapatalk
    It certainly will. I just need to get a '16 on the dyno to build the calibration for it.
    In the Garage:
    2019 RSV4 1100 Factory
    2018 Panigale V4 S
    2017 Tuono Factory
    2017 Yamaha R6
    2011 Ferrari 458
    2019 BMW M2 Competition
    2016 AMG GT S
    2016 Mazda CX5
    2017 Charger Hellcat
    2017 Toyota Tacoma
    OpenFlash Tablet
    Free Tunes || 3-Touch Programming || Digital Gauge Displays || Datalogging || Handheld Convenience || No Laptop Required

  9. #9
    apriliaforum Member
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    Quote Originally Posted by ranman03 View Post
    Do any of the tunes you offer raise the rev limiter?

    -- Randy
    Yes, but only by 150RPM. But that can be set to the OEM value if desired.
    In the Garage:
    2019 RSV4 1100 Factory
    2018 Panigale V4 S
    2017 Tuono Factory
    2017 Yamaha R6
    2011 Ferrari 458
    2019 BMW M2 Competition
    2016 AMG GT S
    2016 Mazda CX5
    2017 Charger Hellcat
    2017 Toyota Tacoma
    OpenFlash Tablet
    Free Tunes || 3-Touch Programming || Digital Gauge Displays || Datalogging || Handheld Convenience || No Laptop Required

  10. #10
    apriliaforum prov-nov
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    Quote Originally Posted by OpenFlash View Post
    It certainly will. I just need to get a '16 on the dyno to build the calibration for it.
    Great, look forward to that.

    Sent from my SAMSUNG-SM-G935A using Tapatalk

  11. #11
    apriliaforum Member
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    Quote Originally Posted by vfr1200 View Post
    Fantastic; what is the conversion number for mph to rpm?
    So stage 2 is for slip on, and stage 3 is for slip on + RSV intake?
    And are the 2017/2018 Tuono maps the same as my 2016 Tuono?
    Is there any loss to having the butterfly in the 2016 stock exhaust vs. the full akra system?
    Would you recommend a stock RSV air filter or an aftermarket like DNA?
    great work.
    -The last graph is shown with RPM in the X axis. But to covert MPH to RPM, just multiply by 92.60
    -Yes
    -Not that I've seen on the dyno
    -I think the OEM RSV4 intake is just fine. It's probably going to have no measurable restriction at these power levels. So using something that doesn't filter as well but can flow more air will have no positive effect.
    In the Garage:
    2019 RSV4 1100 Factory
    2018 Panigale V4 S
    2017 Tuono Factory
    2017 Yamaha R6
    2011 Ferrari 458
    2019 BMW M2 Competition
    2016 AMG GT S
    2016 Mazda CX5
    2017 Charger Hellcat
    2017 Toyota Tacoma
    OpenFlash Tablet
    Free Tunes || 3-Touch Programming || Digital Gauge Displays || Datalogging || Handheld Convenience || No Laptop Required

  12. #12
    Honest always, feared often Micah / AF1 Racing's Avatar
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    Folks...DO NOT GET INTO THE HABBIT OF RAISING REV LIMITERS very much at all, there is a hard-deck on rpm ceiling for a reason, a very expensive lesson I learned a long time ago. Physics have not changed since then.
    Diminished expectations is the key to happiness in life.

    Micah Shoemaker
    AF1 Racing
    9900 IH35N
    Austin, TX 78753
    micah@af1racing.com
    @ShoemakerMicah
    @AF1Racingaustin

  13. #13
    apriliaforum Member
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    Quote Originally Posted by Micah / AF1 Racing View Post
    Folks...DO NOT GET INTO THE HABBIT OF RAISING REV LIMITERS very much at all, there is a hard-deck on rpm ceiling for a reason, a very expensive lesson I learned a long time ago. Physics have not changed since then.
    This is especially true of newer RSV4s which already have a high rev limit. In those cases, we don't raise the limiter at all.
    In the Garage:
    2019 RSV4 1100 Factory
    2018 Panigale V4 S
    2017 Tuono Factory
    2017 Yamaha R6
    2011 Ferrari 458
    2019 BMW M2 Competition
    2016 AMG GT S
    2016 Mazda CX5
    2017 Charger Hellcat
    2017 Toyota Tacoma
    OpenFlash Tablet
    Free Tunes || 3-Touch Programming || Digital Gauge Displays || Datalogging || Handheld Convenience || No Laptop Required

  14. #14
    apriliaforum expert
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    Quote Originally Posted by Micah / AF1 Racing View Post
    Folks...DO NOT GET INTO THE HABBIT OF RAISING REV LIMITERS very much at all, there is a hard-deck on rpm ceiling for a reason, a very expensive lesson I learned a long time ago. Physics have not changed since then.
    Btw Micah do you know if its are any diffrent stuff in the Tuono 1100 engine from the diffrent year...is the piston remade or heads?, cams? , or are all the 1100 engine almost the same?

  15. #15
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    Quote Originally Posted by Micah / AF1 Racing View Post
    Folks...DO NOT GET INTO THE HABBIT OF RAISING REV LIMITERS very much at all, there is a hard-deck on rpm ceiling for a reason, a very expensive lesson I learned a long time ago. Physics have not changed since then.
    I seem to remember the stat being that for each 1000 rpm increase on a motor, that the load on the rod bearings goes up by 42% (this would change slightly depending on the motor). While adding a bar of boost only added something like 12-14% more load.

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