JohnnyPag Spyder 300 Service Manual Download Page 2 | Manualshive

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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

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Summary of Contents for Spyder 300

Page 1: ...S S SP P PY Y YD D DE E ER R R 3 3 30 0 00 0 0 S S SE E ER R RV V VI I IC C CE E E M M MA A AN N NU U UA A AL L L ...

Page 2: ... 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 3: ...cyles reserves the right to make changes at any time without notice of changed parameters and other information Thank you for purchasing your Johnny Pag Motorcycle We wish you a comfortable pleasant and safe ride in the future Special Attention If you operate your Johnny Pag Motorcycle without following traffic laws and instructions in the manual under abnormal conditions such as driving on off ro...

Page 4: ... always pay close attention to your local traffic safety laws You should always inspect your motorcycle before riding Warning Warning If the engine must be running to The battery electrolyte contains do some work make sure the area sulfuric acid Protect your eyes is well ventilated Never run the engine skin and clothing In case of in a closed are The exhaust contains contact flush eyes thoroughly ...

Page 5: ...mbly Lubricate any sliding surfaces before reassembly 6 After reassembly check all parts for proper installation and operation 7 Use only metric tools when servicing this motorcycle Metric bolts nuts and screws are not interchangeable with English fasteners The use of incorrect tools and fasteners may damage the motorcycle WARNING When riding your Johnny Pag Motorcycle you must always pay attentio...

Page 6: ...G WARNING Motorcycles are sensitive to changes in weight distribution Improper loading of cargo can impair your motorcycles performance and stability Keep cargo low and close to the center of the motor cycle Load weight equally on both sides of your motorcycle to minimize imbalance The further weight is located from your motorcycles center of gravity handling can be greatly affected You should alw...

Page 7: ...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 Avoid attaching any electrical equipment Otherwise it can bring trouble to the electrical system Accessories not installed by an authorized JPM dealer will void the warranty ALL SERVICE WORK...

Page 8: ...ontrol horn button Headlight high beam switch turn signal switch 4 Left fuel cap non functional 5 Front brake lever 6 Throttle grip 7 Right handlebar control starter button headlight switch engine cut off switch 8 Dash 9 Right fuel cap functional 10 Ignition switch 3 4 6 7 8 9 10 1 2 5 ...

Page 9: ...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 Rear left turn signal 15 Taillight 16 Front Reflector 17 Rear Reflector 6 5 8 11 12 14 13 16 17 15 7 9 10 4 1 2 3 ...

Page 10: ...ght 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 Front fork 15 Front right turn signal 16 Front Reflector 17 Rear Reflector 1 2 3 9 11 15 10 5 under bike 4 8 6 7 17 13 14 12 16 ...

Page 11: ...Page 11 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 2 4 3 6 5 7 1 ...

Page 12: ...n 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 D Move the ignition switch to the vertical position the circuit is off and the engine is cut off insert the key to lock it ...

Page 13: ... 2 to the corresponding direction The front and rear turn signal will flash until the turn signal switch is pushed it Pushing in the switch will disengage the turn signal and the lights will stop flashing 3 Hign Beam Switch The high beam switch is located on the left handle bar When the high beam switch is in the on position both high and low beam lights should be on When the high beam switch is i...

Page 14: ...r clockwise or clockwise remove the key and close lock cover 3 Turn the engine cut off switch to the on position and press the electric start button at this time slightly apply some throttle 2 Head Light Switch The head light switch has three positions Low high and high running 3 Engine Cut off Switch Engine cut off switch is located on the right handlebar controls When the engine cut off switch i...

Page 15: ...k 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 16: ... 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 To close the cap push the cap down and turn it 90 degrees clockwise The left cap is a fake and used for show only ...

Page 17: ... now stopped Turn the petcock handle straight up facing the gas tank to place the petcock in the ON position see petcock image 2 Fuel is supplied normally fuel flows into the carburetor Turn the petcock until it faces straight down to place the petcock in the Reserve position see petcock image 3 The reserve fuel supply is only used when the normal fuel runs out Petcock image 1 Petcock image 2 Petc...

Page 18: ... will help insure a safe ride It will only take a few minutes and can help detect problems before they progress to failure Oil level check level and add oil if necessary Front and Rear brakes check operation and adjust if necessary Tires check condition and pressure Throttle check for smooth operation all the way through open to close in all steering positions Lights and signals check that the hea...

Page 19: ...il quality is the chief factor affecting engine performance and service life The motorcycle uses engine oil SAE 10w 40 API SG when being sold Use 10w 30 after the first 150 mile break in period There is no external oil filter Recommended cleaning of the oil screen is every 1000 miles OIL LEVEL Check the oil level before each ride To do this remove the dipstick 1 and wipe it clean Reinsert the dips...

Page 20: ...l screen onto the oil pump and reinstall the oil pump onto the engine Replace the crankcase gasket and install the right side crankcase cover Refill the oil to the correct level Please call your local JPM dealer to get replacement gaskets and oil screens if necessary Part numbers can be found on in your parts book or by visiting JohnnPag com SPARK PLUG REPLACEMENT CAUTION Be sure the ignition is o...

Page 21: ...ECTION AND ADJUSTMENT Roll on the throttle from a closed position Be sure that the throttle is smooth all the way through from close to open Check that the cables are in the correct position all the way to the carburetor Check that the cables are not frayed Check the play in the throttle cable Adjust the play by turning the upper adjusting nut 1 until the throttle play is at the desired setup Lock...

Page 22: ...ckwise 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 Once the desired play is been obtained tighten the jam nut 2 1 2 1 ...

Page 23: ...g the fluid level This can be done visually via the fluid check window 1 If necessary add brake fluid DOT 4 To remove the pads Remove two bolts 1 from caliper to fork leg mounting bracket Slide caliper off rotor Remove allen head pins 2 Discard old pads Make sure spring stays facing the same direction install brake pads Install both allen head pins 2 If needed pry apart pads slide on a disk and in...

Page 24: ...ull If necessary add brake fluid DOT 4 To remove the pads Remove bolts 1 from caliper Slide caliper off disk Remove allen head pins 2 Discard old pads Make sure spring is facing the same direction install new pads pad with arm on the side closest to the wheel Install allen head pins 2 If needed pry apart pads slide on a disk and install mounting bolts 1 to fork leg ...

Page 25: ...ddition these steps should be taken before storing the motorcycle Clean and dry the motorcycle Wax all painted surfaces Drain the fuel from the tank and carburetor Spray the inside of the gas tank with an anti rust inhibitor WARNING Wear safety goggles while working on the engine With the spark plugs out oil may come out of the plug holes ...

Page 26: ...il Remove battery Negative side first be sure the ignition is in the off position Inflate the tires to their recommended pressure Store the motorcycle with both wheels off the ground Store the motorcycle covered out of direct sunlight or rain Keep the temperature variation to a minimum Spray all rubber fittings with a rubber preserver ODOMETER READING MILES KM ...

Page 27: ...000 14 484 Fuel line I I I I I Throttle operation I I I I I Carburetor 1 C C C C C Air filter 2 I I I I I Spark plug I I I I I Engine oil I I I I I Oil filter I I I I I Timing chain tension 1 A A A A A Valve clearance 1 I I I I I Chain 2 L L L L L Rear brake system I I I I I Rear brake pad wear I I I I I Brake line I I I I I Front brake system I I I I I Front brake pad wear I I I I I Lighting I I ...

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