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Aftermarket Exhaust? you need to read this...

175K views 291 replies 56 participants last post by  randomtone  
#1 ·
If you have replaced the stock exhaust system on the Scrambler with a freer flowing aftermarket unit that eliminates the stock catalytic converter - then a remap is certainly in order.

I don't care if your manufacturer of choice has stated "no remap required", as this is total bunk - they all lie (it would put a damper on their sales numbers otherwise).

The simple fact is this - running a freer flowing exhaust, without the CAT - will lean out your bike to almost dangerous levels. Running excessively lean on an air-cooled motor is not a smart thing to do. It raises exhaust and head temps considerably. Water cooled bikes can handle this temperature increase much more effectively, but not this bike. The Scrambler is already too lean in stock form, and if you make intake and/or exhaust mods you will lean it out even further.

Besides this obvious reason, there are also others. Adjusting the fueling will ensure that you are getting the most power out of your setup, and will also fix the many other fueling related "oddities" with this bike. It will run stronger, cooler and low end response will be dramatically improved (bye-bye "jerkiness", nothing but smooth power will remain).

I just got done spending almost an entire month dissecting the fuel delivery system and re-tuning my Scrambler - doing so has rewarded me with a MUCH smoother running bike, with greatly enhanced HP and torque - along with a much cooler running motor.

There are several ways you can accomplish much the same, ranging from a moderate investment in time, expertise required, and money - to a lot more of each (if you so desire). Here is a "rundown" of the options available at the time of this posting...

Piggyback Units
One of your options is to have someone install a "piggyback" type unit (like a Power Commander or similar).

Devices such as these are programmable boxes that sit behind you ECU. They replace the fuel mapping that is contained in the ECU with mapping of their own.

These type of units have some distinct disadvantages, though.

The Scrambler actually runs two different kinds of fueling systems. The first (and most basic) is a simple open loop system that relies on fuel mapping. The ECU monitors speed, rpm's and throttle position and delivers fuel based on a table (fuel map). The "piggyback" units replace the maps in the ECU with their own internal mapping in this scenario, delivering alterable amounts of fuel. If this was the only thing that affected fueling on tis bike, these would be more than adequate - but it's not the "only thing".

The Scrambler (like most modern bikes) also has a closed loop system in place. There are oxygen sensors in place that monitor rich or lean conditions present in the exhaust systems, and send feedback to the ECU. The ECU then adjusts fueling accordingly (but at MUCH too lean a state). This only happens when the throttle and rpm's are relatively stable, which can be often, and the piggyback units will NOT address this issue.

The other problem with these "boxes" is that if they fail, your bike will not run, leaving you stranded (and I've had one fail before).

A much better solution, IMO, is to reprogram the ECU itself. Doing so give you the most control over all of the systems, with the least potential for failure.

At this time, there is only one option (albeit with some "sub-options") to accomplish this - Rexxer.

Rexxer Tuning
With Rexxer, you can reprogram the ECU itself, altering the internal mapping, along with having control over a bunch of other parameters at the same time. You can choose to disable the "closed-loop" portion the system - the o2 sensors - if you wish, which greatly enhances overall "drive-ability".

You have 3 basic option in this scenario...

The first - and most simple - is to send them your ECU for re-flashing. There is a form that you fill out, listing all your mods & other options requested - and they reprogram your unit and ship it back within 48 hours. You will have new mapping that matches your particular setup - and have the option for them to disable the 02 system. This is the option that is suitable for most people, it requires no technical knowledge on your part and is very easy to do. The supplied mapping is VERY good, even though it was not tailored to your exact bike, and you can expect anywhere from 4-6 hp increase, with greatly enhanced drive-ability. The cost for this service is $300.

The second option is to take your bike to an authorized Rexxer dealer. They can reprogram the ECU to your EXACT bike, using a dyno. This is the way to get the most out of your individual setup. I have done this myself (I'm lucky to have access to a dyno - and years of tuning experience), and gained a whopping 9.5 HP over stock. The cost for this is variable.

The third option is to purchase a Rexxer "User" unit. This is a small "black-box" that interfaces with your ECU via the diagnostic port (cable is supplied). It comes with one map tailored to your setup (additional maps are optional). With this setup you get all the advantages of "option 1", with the added ability to alter other fueling parameters at any time. You can disable, or re-enable the 02 system for example, and clear error codes. You can also reset service indicators. Your original stock mapping is retained in the unit, and can be restored at any time. This cost for this option is $600.

I'm not affiliated with Rexxer in any professional way, and usually do not "gush" about vendors in the performance industry, but this has been simply one of the best experiences I have ever had in many years of doing this.

In the US, the people to contact about any of the Rexxer options is Redline Performance, located in Yorktown Virginia. They are a Ducati dealer, and the headquarters for Rexxer USA. Here is their contact info...

Redline Performance Motorsports
7331 George Washington Memorial Hwy, Yorktown, VA 23692
(757) 989-5000

David (the owner) is the one you want to speak to. He's a pretty busy guy, but always answers emails sent to "david@rexxer.com".
 
#50 ·
IMO, the build quality of the Termi is poor.

AND...

It will cost you almost twice as much as a decent aftermarket pipe with mapping.

AND...

The aftermarket pipe and mapping will out-perform it by a considerable margin.
 
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#51 · (Edited)
Outperform is relative, it's an air cooled 803 SOHC, shrug. You said yourself the clutch will end up slipping without even going too crazy. Price is also high, yes, but shrug 2; what's $1400 on a $10,000 bike? It's a breath of fresh air to me as opposed to the superbike prices. I'm almost certain you have some sort of working relationship with REXXOR for the amount of plugging you do, if not I apologize and I'll GFMS.
 
#54 ·
Seriously?

I have no "relationship" with the people at Rexxer that has compensated me in ANY fashion.

I have purchased EVERYTHING related to my recent mappings entirely from my own funds - and at full retail pricing.

In addition, I have gone to great lengths - in every post I have made on the subject - to point out that there are also alternate ways to address the fueling issues (eg; power commander, etc.)

In my last post in this thread, the one that you have seemingly gotten so "defensive" about, I criticized Termi's build quality and the lack of effectiveness of the accompanying up-key map, along with the expense required. I fully stand behind that criticism as it is well deserved. Many have reported manufacturing defects with this exhaust (whistling, internal welds breaking, etc.), and the lack of performance from the supplied mapping is also well known.

I made absolutely no mention of Rexxer in that post.

You made the conscious decision to go the "Termi" route, your choice - your bike, I'm sure you are happy with it.

But don't get all upset when someone points out viable alternatives to this - ones that actually have tangible benefits - in order to help others be informed.

You don't know me (obviously) but I am the absolute antithesis of a "fanboy" of ANY particular manufacturer or vendor. I'm naturally skeptical of them all - equally - and only make recommendations when the results warrant.
 
#53 · (Edited)
You're correct, I also did not purchase one of the slip-ons. I inspected the full before purchase, and it's hard to **** it up with a simple straight muffler and some headers. As long as the welds are solid, there's not much else that could fail. I prefer Akrapovic myself, but they're always late to the game. There's nothing wrong with buying something else, I went with the full Termi for ease of use and the included UPMAP. As far as the failures go, that's pretty Italian.

And yes, this bike feels pretty sloppy with the stock muffler/cat.
 
#55 ·
No need to defend yourself or your point of view, I said if I was wrong I'd GFMS; and to each their own. Let's hug it out?

Don't get me wrong, I think most of the OEM stuff is ****. I'm just saying it's not THAT bad. I agree with all your points on mapping, never in dispute. I'm just so skeptical personally on the ROI with this bike with regards to performance.
 
#56 · (Edited)
ROI?

A full 10% increase in performance is easily obtained with less than $1000 total investment.

10% is a pretty significant number.

For those not looking for performance, $300 gets you a bike that is actually fueled properly, eliminating the "snatchiness" and low speed stumbling so many have complained about (I'm not is this camp). Plus the bike runs cooler and will be more reliable - long term.

It's kind of funny that you stated that a $1400 outlay was "nothing" in regard to a $10k bike, but now you are questioning ROI.


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#94 ·
ROI?
For those not looking for performance, $300 gets you a bike that is actually fueled properly, eliminating the "snatchiness" and low speed stumbling so many have complained about (I'm not is this camp). Plus the bike runs cooler and will be more reliable - long term.
Tony, two more questions.

with the ZARD low mount i truly feel that my bike is less hot, is it only my impression? I haven't touched anything. else.

I'm also not planning to remap my ECU with Rexxer. I will reset the ECU and, as you said, it will still run lean, fair enough but, will the lean run damage my engine somehow? the original map is programmed to run lean anyway so it shouldn't damage the engine, right?

great thread thanks for all these info buddy.
 
#59 ·
hi, i have the shift tech slip on exhaust on my FT scrambler. i dont know where the ecu is . can you please explain to me how i remove it from the bike ? then would i ship it to redline for reflashing? i would really appriciate your advice and time.

thamk you

Michael Carrera

The ECU is located under the seat, just in front of the storage area, it looks like this...

Image


I would contact David at Redline before proceeding.


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#58 ·
What about the clutch?

Tony, Thanks for all the good info. Last time I heard from you about the Rexxer unit you still had your O2 sensors enabled. Thanks for posting the US Rexxer link, it does look much more user friendly. What about the clutch issue though?You previously stated that it couldn't keep up with only a 8 hp and 3.6 ft/lb increase. It is apparent that with a more open intake that much greater gains are possible. Have you upgraded your clutch? Barnett makes clutch packs and springs compatible with the Ducati 796. I haven't seen the Scrambler listed on there site. I had also been planning on getting a Rexxer user unit but am waiting to decide what type of intake I am going to purchase. And if I get a more open intake will my clutch hold up, or will I have to upgrade the clutch. Have you heard of other problems of clutches slipping badly when approaching a 10% increase in hp and torque. Intake express is claiming 25% gains so there must be a solution. What are your thoughts? :)
 
#60 ·
Tony, Thanks for all the good info. Last time I heard from you about the Rexxer unit you still had your O2 sensors enabled. Thanks for posting the US Rexxer link, it does look much more user friendly. What about the clutch issue though?You previously stated that it couldn't keep up with only a 8 hp and 3.6 ft/lb increase. It is apparent that with a more open intake that much greater gains are possible. Have you upgraded your clutch? Barnett makes clutch packs and springs compatible with the Ducati 796. I haven't seen the Scrambler listed on there site. I had also been planning on getting a Rexxer user unit but am waiting to decide what type of intake I am going to purchase. And if I get a more open intake will my clutch hold up, or will I have to upgrade the clutch. Have you heard of other problems of clutches slipping badly when approaching a 10% increase in hp and torque. Intake express is claiming 25% gains so there must be a solution. What are your thoughts? :)

My clutch issues were solved with some simple "roughing" of the friction plates. Every bike will be different, my suspicion is that my particular setup was a little on the "weak" side.

When you start modifying for performance, and those mods are restricted to intake / exhaust / fueling (as opposed to going into the motor itself) then there is a finite amount of "potential" to be had.

You can tune for peak torque, or peak HP, or any combination of both, but the total gains possible have limits.

It's interesting to look what Intake Express has done so far, their goal was obviously to get he most torque - and the gains are impressive - bit if you look you will see that it comes at the expense of HP gains. They only were able to add 1 hp over base while doing so.

The modifications undertaken where also pretty radical and extensive, requiring massive rework / replacement of the entire intake system.

My opinion is that the Scrambler motor is pretty torquey already, so I opted for a more balanced approach.

At the end of the day, I gained about 8hp, but the real benefit is the way the bike runs overall now. Torque has also been increased, but more moderately, and the fueling has been improved immensely. The power delivery is smooth and linear, through the the entire rev range, and the motor runs measurably cooler.


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#62 ·
My earlier "experiments" had me opening the airbox - in addition to using the BMC race filter, while having the baffle in the exhaust removed. This produced the largest gains, but at the expense of a tremendously loud bike. Too loud for casual use.

I then reverted to refitting the baffle, and doing so made the airbox mod and use of race filter unnecessary.

My final setup is no airbox mods, BMC (non-race) filter, baffled exhaust and disabling of the O2 system.

This is where it will stay for me, tuning is over and my fueling is **** near pefect.

On to other areas that need addressing...




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#69 ·
Anyone tried the remapped ECU with Rexxer mapping yet? I am quite tempted to use this service as the nearest Rexxer point is quite far away and they need to keep the bike for a week so that means two trips. I have been reading positive reviews on the Rexxer mapping and with a different slipon but std headers I think the bike should run well on their mapping for this configuration.
 
#71 ·
That would be my exact setup too, Tony! Good to hear that you like it. If I understand correctly by disabling the O2 sensors you run on the mapping all the time, whereas the O2 sensors enabled keeps the closed loop circuit in which the ECU will try to improve (or lean out) the mixture based on the input of the seonsors, which would likely mean that with a good map you would be better off running the O2 sensors disabled so that the mapping is correct all the time.
 
#72 ·
This is correct.


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#73 ·
I wonder if the Termi Race map disables the O2 sensor and if not, why.

Also instead of disabling the O2 sensor, wouldn't it be better to adjust the parameters of the formula that the ECU uses when calculating the fuel mix it wants depending on the sensor input? Is the O2 system only there for emissions regulations or does it prevent the engine from running rich/lean because of changes in atmospheric pressure, air filter performance etc?

I still felt that I didn't understand this whole rich/lean and O2 sensor thing so I read up on it and from what I understand, the point of the O2 sensor is to get as close as possible to a 14.7:1 ratio regarding air to fuel. This is because at that ratio the catlytic converter works best. A rich or lean mix both result in increased emissions. So it seems that a bike running in the closed loop, using the oxygen sensor data, having a cat, will try to not run lean (or rich). It tries to hit the sweet spot in terms of cat efficiency.

Therefor disabling the O2 sensor can result in running lean or rich, depending on the fuel map in use.

But I think the real kicker is that eliminating the cat will **** up the formula that the ECU uses when calculating the fuel/air mix to use since without cat, the amount of O2 in the exhaust gases will be very different. The ECU will think the mix is too lean/rich and adjust accordingly even if the combustion is fine. Basically it just gets confused because it assumes the cat is still there.


So what I learn from these thoughts is that eliminating the cat but not the O2 sensor can be really bad. But eliminating the sensor too doesn't make it perfect either. Because now the ECU doesn't have enough data to adjust the fueling according to the atmospheric pressure and so on. A fuel map can't be perfect for all circumstances. Ideally the ECU would be made aware of the missing cat and adjust how it reacts to oxygen sensor data.

Now I think having an aftermarket exhaust with cat (remus, akrapovic) but removable baffles plus new fuel map but leaving O2 sensor intact is way better in terms of improving sound while keeping the engine healthy.

Please feel free to correct me if any of the above is wrong. I am a complete novice when it comes to these things.
 
#74 ·
I think it makes sense but I am by no means an expert. As I replaced my exhaust by a slipon without cat I think there is no need for the O2 sensors; indeed this means that the mapping will determine fuel mixture all the time, but I think this is not bad as the closed loop is only in effect for a small part of the running anyways. The mapping made by Rexxer should be better for all circumstances than the stock mapping with a different slipon/no cat. There will be differences between running at sea level and in the mountains, but that would be the case with the standard mapping and closed loop system in place too, as the closed loop does only work in limited circumstances.
 
#76 ·
It would be interesting to hear what mpg s you guys get with the remaps and setups you made. While I'd love a better throttle response, I'm not sure I'd give up 10 mpg for it. Thinking about it, ideal would be for the ecu to have two maps, one the one we have for distance either off-road or in the middle of nowhere, the other for weekends and around town. Just a pipe dream, I know.
 
#80 ·
Hey tony, very informative thread! Thanks for posting all this info.

Noob question: is that the cat on the stock icon exhaust attached to the muffler and not part of the header? The reason why I ask is I don't see the cat in the pictures (don't have my bike yet) and I plan on only getting a slip on competition werkes exhaust, bmc air filter, and rexxer user unit as fat as performance mods go. Trying to find out if I have to swap out the header as well to eliminate the cat.

Thanks!


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#81 ·
CAT is part of stock muffler and takes up the space directly under the swingarm. Take a look at your bike, you will see what I mean.

Fitting an aftermarket can will eliminate the CAT (unless your can of choice has its own CAT, a select few do).

It is very important to remap if the CAT is being eliminated (and beneficial even if it is not).

Adding power will always come with a decrease in fuel economy, as stated any percentage in gains will show a corresponding decrease in mpg percentage (roughly).

Example, adding 5% more power one should expect an equivalent reduction in fuel economy (roughly 5%).

There is no such thing as "free lunch".


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#83 ·
It is a drop in replacement, no mods needed. I bought mine via eBay (Italy).


According to Rexxer, it does not do a lot in terms of output - apparently +1 HP on top end and -1 HP in the midrange, but it is more durable and should sound better. I still need to install mide and will do so as I am waiting for my remapped ECU to return from Rexxer.
 
#85 ·
Thanks, guys. One last question (for now). The Rexxer unit can clear service warnings, correct? So no need to depend on the dealer to clear the 600 mi and 7500 mile service interval warnings for you?

That's honestly one of the biggest reasons why I want the User unit instead of sending my ECU in to get it flashed.

thanks!


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