How to solve Slow Draining Fuel Filler on AJP PR7!

Update: After a long week in Wales riding TET and fueling up more often than usual, it appears that this mod really works! It didn’t turn fueling-up into super fast one, however it no longer takes 5 minutes to fuel up from empty tank to full! So I am happy with it!

If you own ajp pr7, you will know how painfully boring fuel up on ajp pr7 is!

After a closer look at the breather pipe and fuel tank I realised that the acerbis tank actually has two holes to let the air out and in! 

However, both fittings have very small holes in them- only 3 mm or so. And to make things more interesting – two pipes that come out of the tank, join into one before reaching 1 fitting located on the fuel filler.

While looking at all that, I asked myself:

“why not two?”

And that’s what I did, sort of.. 

First of all I took the fittings out of the fuel tank, and noticed that the fittings themselves had very thick sidewalls. Using a slightly wider drill bit I widened it up by another mm. 

Next was to reroute new pipes, I used braided pipe as I ordered the wrong one, and since braided is thicker too, I had to reuse some of the older piping. Joined both new pipes at the point where filler meets the fuel tank, and from there up- old thinner tubes. 

Fittings

To hold the new tube to the air filter box, I used tube fitting like originally was used. Funny enough, AJP used the same fitting to hold the rear brake line attached to the swingarm! Replaced that with a normal hose clamp (P-Clip) to keep the brake line secured. Attached the fitting to the airbox with a couple of rivets – same way like the original one.

And for the final bit, to attach a breather tube to the fuel strainer I used barbed bulkhead tube fitting as I couldn’t find anything better at that time, I just cut the unnecessary end of it as well as shortening the barbed end to about 1cm.

Drilled a hole in the flat spot on the fuel strainer, screwed it in and connected the tube.

Job done! 

In the worst case if it wont drain quicker, at least I’ll be able to fit more fuel in the tank – a whole 5ml more or so!

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AJP PR7 Faults, Fails and Fixes

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