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JohnnyPag Spyder 300 Service Manual

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Summary of Contents for JohnnyPag Spyder 300

  • Page 2: Table Of Contents

    Table of Contents Preface……………………………………………………….……3 General safety Warnings……………………………..………..4-7 Parts Locations………………………………………...…………8 Left Side of Spyder……………………………………………….9 Right Side of Spyder………………………….…………………10 Parts Functions…………………………………………………..11 Ignition Switch………………………………………………...…12 Left Handlebar Controls…………………………………..…….13 Right Handlebar Controls………………………………………14 Rear Shock Absorber………………………………………..…..15 Fuel Tank and Cap…………………………………..………..…16 Petcock Instructions…………………………….………….……17 Tires………………………………………………………...…….18 Pre-ride Inspection……………………………..…………….….18 Maintenance……………………………………….…………19-25 Service Schedule…………………………………………………26 Page 2...

  • Page 3: Preface

    Preface This manual introduces you to the basic operations and methods of maintenance for your motorcycle. Please read this manual carefully before driving your motorcycle. Proper operation and maintenance of your motorcycle will ensure less troubles and optimum performance and service life. Johnny Pag Motorcycles authorized service dealers in various locations will provide you with more technical consultation and after-sales services.

  • Page 4: General Safety Warnings

    IMPORTANT NOTICE The engine for your Johnny Pag Motorcycle rotates at a high rate of speed. In order to make sure that the engine can run normally, and to prolong its service life, please operate your motorcycle according to the following regulations: 1.

  • Page 5: Service Rules

    Service rules 1. Use genuine Johnny Pag Motorcycles or JPM recommended parts and lubricants or their equivalents. Parts that don’t meet Johnny Pag Motorcycles design specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3. Install new gaskets, O-rings, cotter pins, lock plates, etc. When reassembling. 4.
  • Page 6 CAUTION The temperature of your motorcycles exhaust is very hot! When ridden. The passenger should always wear boots or shoes high enough to cover his/her ankles to prevent burn related injuries. The rider should wear close-fitting clothes to prevent loose clothing from being caught on the handlebars, kick starter, foot pegs, and tires. MODIFICATIONS WARNING Modification to your motorcycle or any changes to its original equipment may render...
  • Page 7 Accessories produced by our company have undergone special design and testing. Users will take responsibility for their selection, installation and use of accessories not produced by our company. Please obey safe riding rules and follow the next points: • Carefully check your accessories, make them out of sight line, reduce distance between them and the ground and side dip angle, and keep suspension or steering devices from moving or affecting handling.

  • Page 8: Parts Locations

    Parts Locations 1. Mirrors (mounting location ) 6. Throttle grip 2. Clutch lever 7. Right handlebar control (starter 3. Left handlebar control (horn button, headlight switch, engine button, Headlight high beam cut-off switch) switch, turn signal switch) 8. Dash 4. Left fuel cap (non functional) 9.

  • Page 9: Left Side Of Spyder

    Left Side Spyder 1. Front rotor (left) 2. Front brake caliper (left) 3. Front Headlight 4. Front left turn signal 5. Gearshift lever 6. Foot peg 7. Engine 8. Choke valve 9. Petcock 10. Kickstand 11. Engine serial number 12. Left side exhaust 13. Dash 14.

  • Page 10: Right Side Of Spyder

    Right Side Spyder 5 (under bike) 1. Rear right turn signal 2. Rear brake caliper 3. Rear rotor 4. Right side exhaust 5. Rear shock 6. Seat 7. Carburator 8. Fuel tank 9. Rear brake pedal 10. Vin number 11. Front brake caliper (right) 12. Front rotor (right) 13. front wheel 14.

  • Page 11: Parts Functions

    Parts Function 1. Left turn signal indicator 2. Odometer 3. High indicator 4. Neutral gear indicator 5. Speedometer 6. Right turn signal indicator 7. Ignition switch Page 11...

  • Page 12: Ignition Switch

    Ignition Switch The ignition switch (7) is in the middle of the fuel tank. A. When the ignition switch is in the vertical position, the circuit is closed off; the engine can’t be operated; Key can be removed. B. Turn the ignition lock counterclockwise or clockwise. If the neutral gear indicator is on, and the odometer is on, the engine will start.

  • Page 13: Left Handlebar Controls

    Left Handlebar Controls 1. Horn button 2. Turn signal switch 3. High beam switch 1.Horn Button Press the horn button once to sound the horn if necessary. 2.Turn signal switch The turn signal switch has three positions. If turning right or left, move the turn signal switch (2) to the corresponding direction.

  • Page 14: Right Handlebar Controls

    Right Handlebar Controls 1.Electric start button 2. Headlight switch 3.Engine cut-off switch 1.Electric Start Button The start button is located on the right handlebar controls. 1. make sure the gear is shifted to neutral and the fuel switch is on position. 2.

  • Page 15: Rear Shock Absorber

    Rear Shock Absorber Rear shock absorbers (there are two rear shock absorbers) are located under the middle of the frame. The rear shock absorbers can be adjusted for different ride heights by a Johnny Pag Motorcycle dealer. Adjuster Page 15...

  • Page 16: Fuel Tank And Cap

    Fuel Tank and Cap Fuel tank capacity is 3.5 gallons with .75 gallons of reserve. We recommend you to use unleaded gasoline only. CAUTION Don’t over fill the tank. After refueling, make sure that the fuel cap is closed securely. How to Open a Fuel Cap The right fuel cap is used for filling your fuel tank, turn it 90 degrees counter clockwise to open it.

  • Page 17: Petcock Instructions

    Petcock The petcock is located below the left side of the fuel tank. Turn the petcock handle to face the rear of the motorcycle to place the petcock in the (OFF) position “see petcock image #1”. Fuel supply is now stopped. Turn the petcock handle straight up facing the gas tank to place the petcock in the (ON) position “see petcock image #2”.

  • Page 18: Tires

    Tires Please refer to the tire manufactures specifications (located on the tire) for inflation specifications. WARNING Operating a motorcycle with excessively worn tire will adversely affect traction, stability and handling. Always check tire pressure and tread before riding. Inspection should be made while the tires are cold.

  • Page 19: Maintenance

    Break In During the first 250 miles, avoid full throttle use. Keep the engine under 6000 rpm, the maximum speed should not exceed 50 MPH. Breaking in the engine correctly will ensure long engine life. NOTE: Motorcycle must be serviced between 100-105 miles by an authorized Johnny Pag Motorcycles dealer to keep warranty valid.
  • Page 20 Running the engine with insufficient oil can cause serious damage to your engine. CHANGING ENGINE OIL To drain the engine oil, remove the engine drain bolt (1). Let the oil drain completely before refilling the case with oil. If cleaning the oil screen, be sure to wait until all the oil has drained before removing the right side crankcase cover (2).
  • Page 21 AIR CLEANER REPLACEMENT • Remove seat • Remove right side cover • Remove air filter cover • Slide out filter element and replace with new element • Inspect the screen, clean if needed • Install air box cover • Install right side cover •...
  • Page 22 IDLE SPEED AND ADJUSTMENT First warm up the engine. Adjust the idle by turning the adjustment screw (1) counterclockwise and clockwise. The correct idle speed is 1500 + 150 RPM. CLUTCH ADJUSTMENT To adjust the clutch, be sure the front wheel is in the forward riding position. Adjust the play in the clutch by tightening and loosening the adjuster bolt on the clutch perch (1).
  • Page 23 VALVES Valve clearance for the 300cc motors are .06-.10 intake and exhaust BRAKES WARNING: Brake fluid is very dangerous. Avoid contact with mouth and eyes. If ingested or in contact with eyes, call 911. FRONT BRAKE Start by checking the fluid level. This can be done visually via the fluid check window (1). If necessary, add brake fluid ( DOT 4 ).
  • Page 24 REAR BRAKE Start by checking the fluid level. This can be done visually by removing the master cylinder reservoir cap (1). Check that the master cylinder is at ¾ full. If necessary, add brake fluid ( DOT 4 ). To remove the pads: •...
  • Page 25 STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration. In addition, these steps should be taken before storing the motorcycle. • Clean and dry the motorcycle • Wax all painted surfaces •...
  • Page 26 ODOMETER READING (MILES/ KM) • Remove spark plugs and pour a tea spoon of clean engine oil in each cylinder. Hit the starter button a few times to coat the inside of the cylinder with oil. • Remove battery. Negative side first (be sure the ignition is in the off position) •...

  • Page 27: Service Schedule

    100-150/ 160-241 1000 / 1610 4000 / 6437 6500 /10,460 9000 /14,484 ITEM NOTES Fuel line Throttle operation Carburetor Air filter Spark plug Engine oil Oil filter Timing chain tension Valve clearance Chain Rear brake system Rear brake pad wear Brake line Front brake system Front brake pad wear...

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