Aprilia Falco Brake Line Construction

If you can't find a kit for the Falco, or if you only want to do the front lines (this is probably all anyone needs), you can build your own lines. There are two ways of doing it. Some companies, such as Goodridge, sell stock screw together parts. You order the length lines you want and the screw on (AN) fitting and put it together. If you want to go to an odd length, or just want the cheapest possible solution, you can order the raw materials to put together your own 2000 psi lines.

The most famous of racing plumbing suppliers is Earl's Performance Products. In the states, they are distributed by WM Engineering (1-800-886-3275), out of Wisconsin. There also have UK, Australia and Japan distribution now too. The lines suitable for brake use are called "Speed-Flex". These are available pre-assembled (like Goodridge), or as raw line sold by the foot, which anyone with moderate skills can safely assemble. Ask for a catalog when you order and assembly instructions are included in the appendix.

Parts list, Front Brake Line

Section	Measurement	Qty	Part No*	Price*
Line, master cylinder to junction	Plastic coated Speed-Flex hose, -3 size	9 inches	n/a	~$2.25
Line, Junction to close caliper	Plastic coated Speed-Flex hose, -3 size	14 inches	n/a	~$3.50
Line, Junction to far caliper	Plastic coated Speed-Flex hose, -3 size	18 inches	n/a	~$4.50
Banjo fitting, master cylinder	10mm, -3 size, straight adj.	1	600433	$13.18
Banjo fitting, caliper	10mm, -3 size, 90 degree, non adj.	2	601533	$19.74
Banjo bolt, single	10mm x 1.0	3	977517	$11.40
Tee, Hose-Hose-Hose	-3 size	1	6453533	$39.47
Total				$94.04

Notes

Part numbers and prices are from an old catalog--order by part description to be safe. Part numbers are for ALUMINUM fittings (0.425in banjo heights). Plated steel and stainless steel are also available.
Hose is sold by the even foot only, so you have to round the prices up.
Banjo bolts come with two crush washers.
Aluminum fittings are 50% more expensive than steel. Also, adjustable fittings were specified when available, but are 33% more expensive than non-adjustable. Long fittings were specified in all cases. Shorty, non-adjustable straight fittings are available.
If you want to eliminate the very expensive junction and run two independent lines, order enough extra hose to run the upper line length again (9 inches, $2.25), order an extra straight banjo (part no. 600433, $13.18) and order a double-banjo bolt (part no. 977519, $4.55) instead of the single for the master cylinder. Total cost will be $74.55.

Parts list, Clutch Line

Section	Measurement	Qty	Part No*	Price*
Line, master cylinder to slave cylinder	Plastic coated Speed-Flex hose, -3 size	34 inches	n/a	~$8.50
Banjo fitting, master cylinder	10mm, -3 size, straight adj.	1	600433	$13.18
Banjo fitting, slave cylinder	10mm, -3 size, 90 degree, non adj.	1	601533	$9.87
Banjo bolt, single	10mm x 1.0	2	977517	$7.60
Total				$39.15

Notes

Earls recommends -4 line for clutch lines. It seems the motorcycle performance parts industry uses the same as brake lines (-3). Perhaps the clutch travel in a motorcycle clutch is very small compared to a car slave cylinder.
The banjo with bleed screw is not available from Earls (or it didn't used to be). If you are reusing your banjo bolt you can delete a banjo bolt from the parts list.

Parts list, Rear Brake Line

Section	Measurement	Qty	Part No*	Price*
Line, master cylinder to slave cylinder	Plastic coated Speed-Flex hose, -3 size	28 inches	n/a	~$7.00
Banjo fitting, master cylinder	10mm, -3 size, 30 degree, adj.	1	600533	$13.18
Banjo fitting, caliper	10mm, -3 size, straight adj.	1	600433	$13.18
Banjo bolt, single	10mm x 1.0	2	977517	$7.60
Total				$40.96

Notes

The stock line uses a 30-degree bend on the master cylinder, but a straight fitting would probably do just as well.

If anyone does make their own lines for the Falco, let me know how it goes.

Go back to the Falco home page.

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