Vacuum hose and fuel line questions

[philosophydoc]

Greetings.

I am rebuilding a scooter that I bought cheap, but am at a loss for answers to a few simple questions. (Honestly, these questions seem so stupid I feel bad asking them, but since I have been unable to find any sort of diagram that would tell me how to hook things up, I have no other option. I have searched the board for days to make sure I'm not asking something to which an answer already appears...apologies if I missed it.)

The scooter is a JCL MP250E -- engine is CF Moto 244cc Helix clone. It had 130 miles on it when the rocker arm broke, and the original owner literally "ripped" it apart to fix it. (And I mean ripped - he cut about six electrical wires which I am still tracing, lost the CDI and voltage regulator, etc.) He replaced the rocker arm and then lost interest in doing anything more. I bought the scooter for $750, and am slowly putting it together. I assumed all the parts would be with it, but there's stuff in the "parts" box he gave me that don't seem related to the scooter at all. (The guy owns Killermotorsports in Dallas, and hence some of the parts come from other scooters).

But enough of my tale of woe...

Here's a photo of the engine compartment:



QUESTION 1: the vacuum hose whose open end is sitting on top of the cylinder head; where should it go? (It comes off the main leg of the white plastic "T" connection at the bottom of the photo. The left end of the "T" goes to the PCV valve (another question there); the right end splits again and both those hoses (I believe) attach to the carb. But the last hose...? I can't see any exposed nipple to which it should attach. I know there is another vacuum line coming off the top of the gas tank, but I can see where that connects here:



QUESTION 2: if you look back at the first picture, just under the top of the carb, you'll see a fuel line hose coming out, and turning right (you can see the inline fuel filter on it). I assumed this would connect to the gas tank, but there is already a hose coming off the tank (not pictured). I have searched for a fuel pump, but if there's one here, I can't find it.

Today I noted that the unattached ends of both these hoses (the one with the inline filter, and the one coming from the tank) are not cleanly cut, but have been torn (each has a jagged edge). I hoped this meant that my two hoses were really one, but unfortunately the torn ends don't match up. Still, it makes most sense to me that one hose (with an inline fuel filter) should run from the tank to the carb. If not, to what do these two fuel lines hook up to?

I have a gazillion other questions, but for now these will do. Thanks in advance...I have learned so much here already.

[earlwb]

Ok vacuum lines are simple, once you start at A and work through to B, etc.
off the intake manifold you have a vacuum line going to a Tee connector or more Tee connectors.
basically a vacuum line goes to the carb, another vacuum line goes to the fuel pump, then a vacuum line goes to the PAIR system valve, and you may have a vacuum line going to the carbon canister for the fuel tank. They may have one or two fittings on the intake manifold and the approriate number of Tee fittings to get it to work. You can block off or plug all the vacuum lines, except for the fuel pump and carb. It won't hurt the engine operation. You can then hook them up later as needed, if you want to.

The fuel tank has a vent tube that goes through a one way valve (lets air in but not fuel out), and then thew vent line goes to the carbon canister. They then have a little large tube going to the air filter box off the carbon canister. The pic above of the roundish unit with a fitting on each side looks like a one way fuel tank vent valve to me.

The fuel pump is a typical pulse pump unit where they use the intermittent vacuum pulses off the engine intake to operate the diaphram inside the pump. They run a fule line off the bottom of the fuel tank through a fuel filter to the pump, and then the fuel line goes to the carb on the engine.

the carb usually has a rubber drain tube on the bottom with a screw valve on the end, so you can remotely drain the carb as needed.

I suspect the dealer was using your bike as a parts bike and was scanvenging parts off of it.
being in a hurry the mechanic would just crudely tear or yank the item of interest off of it.

You can go to the www.roketa.com website and under "mopeds" look for scooters similar to yours and download the circuit diagrams. Most scooters are very generic and the wiring is basically the same. They are notorious for changing wire colors at the factory, so wire colors may or may not match anyway. But it gives you an idea of what to trace and look for.

[philosophydoc]

Many thanks, earlwb...I now see that while I had searched the parts page on the JCL website for my scooter (www.jclusa.com/MP250E-sellparts.htm) I had spent my time searching the engine assembly diagram looking for reference to a fuel pump. Turns out the pump is referred to as the "VACUUM SWITCH,FUEL" on the frame assembly diagram. Ugh... I'll order a Mifuni pump today.

Am replacing all the fuel lines with much sturdier 1/4 inch tubing and hose clamps, and will likely do the vacuum lines as well.

Have started trying to trace the electrical, and it's a challenge. For instance, consider this photo, where I have laid what appears to be the rectifier next to the only molex connector it fits:



Again, I am trying to match up the parts that came in the now infamous "box o'parts" with the bike. On the JCL website listing the electrical parts for this scooter (www.jclusa.com/parts_details_table.php?proid=308&lb=955&page=JCL-MP250E-sellparts-WIRINGASSEMBLY(2), it identifies two different parts (10 and 13) as both being "rectifiers" for this scooter. Here is one (www.jclusa.com/upfiles/MP250E-02-11.jpg). (Now I know that in another of your posts, you referred to as the "voltage regulator.")

The second "rectifier" is shown here (www.jclusa.com/upfiles/MP250E-02-13.jpg), and appears to be what most online scooter parts stores call the rectifier. Unfortunately, I have nothing like this in my box, nor do I have any molex connector that will fit this type of rectifier (a flat, four blade connector). The part I do have that fits (in the above photo) has the following letter number combination (upside down) on its side -- FLP0805. When I Google "FLP0805 scooter" I get a number of hits that identify that part number as being a rectifier/voltage regulator for various ATVs, scooters, etc. Again, since the molex connectors fit, and the part number corresponds to a rectifier, I am inclined to believe it is the correct part for this bike.

(You, like me, may ask "If this truly is a JCL scooter, why is my rectifier not the same as the one listed on the JCL website?" As best I can determine, this scooter was originally sold as an Apollo Ani 250, Apollo having bought out Orion. Now it seems JCL has taken over Apollo. Still, when I gave JCL the VIN number off my scooter, they claimed it doesn't show up in their system as a JCL product. Hmmm...)

Anyway, do you see any reason why the connection shown above shouldn't be made?