USER MANUAL
Contents
1. Brake piston and dust cover Piston and rings Annually used Front and rear wheels Every time Fuel system used Whenever necessary If damaged Exhaust seal Nuts bolts and other fasteners fdamaged If damaged ITC necessary Every time Whenever Petrol tube y If damaged used necessary i Wh used necessary Chassis protective adhesive elements damaged o 00 i damaged Sump protector JTG HOMOLOGATION All the components fitted in this vehicle comply with legal homologation requirements including the identification marks on part that require them Pay attention to the component that are compulsory for using the motorcycle on public roads and must be present on the vehicle in order to pass the Vehicle Technical Inspection Test Registration plate holder Speedometer Lighting system and reflectors Indicators Horn Rear view mirrors Steering lock Manufacturer s identification plate Air filter restrictor Exhaust system with catalyser Silencer Carburettor jets Side stand IMPORTANT NOTE The vehicle is also supplied with a RACING KIT containing additional components Bear in mind that the modifications provided by this kit are NOT covered by the vehicle homologation N TROUBLESHOOTING IMPORTANT NOTE For all internal adjustments or replacement of parts that are not normal wearing components it is recommended to take the motorcycle to an auth2. WY JTG JT300 USER MANUAL JTG Welcome to JTG Thank you for the confidence you have shown in our brand by purchasing this motorcycle designed for Trial As a JTG user you will enjoy a product that offers innovation where strictly necessary without excesses incorporating characteristics such as quality prestige and exclusivity Designed by off road professionals to offer comfortable and effective service without forgetting a competitive spirit that will enable you to experience the performance of a winner ready at your disposal JOTAGAS S L 2012 SU JT JTG ADVISES YOU Please read this user manual carefully before using your motorcycle In it you will find all the instructions necessary for correct operation of the machine as well as for your own safety enabling you to attain optimum maintenance and service life from the very first day Please pay special attention to notes bearing these symbols ATTENTION This symbol refers to aspects which if ignored could cause damage to your motorcycle Non observance of these warnings could render the guarantee void AN PRECAUTION This symbol refers to aspects which if ignored could result in physical danger to the user In addition to the specific warning notes this manual also contains other tips for better use of your motorcycle as well as better adjustment and control of important features of the vehicle JTG reserves the right to modify this
3. Bent steering shaft Take bike to a specialised workshop Suspension too hard Too much oil in fork Remove excess oil Replace oil with correct density Oil in fork too dense Take bike to a specialised workshop Twisted or bent fork Adjust tyre pressure Excessive tyre pressure Adjust rear shock absorber Rear shock absorber badly adjusted Suspension too soft Low oil level in fork Add the right oil to the specified level Replace oil with correct density Oil with excessively low density Adjust rear shock absorber Handlebar vibration Worn tyre swinging arm or bearings Take bike to a specialised workshop worn Rim out of true Take bike to a specialised workshop Badly aligned wheel Take bike to a specialised workshop Steering shafts handlebar supports or Tighten nuts and fasteners to fasteners with play specified torque Brakes working badly Pads worn Change pads Discs worn Change discs Loss of brake fluid Check circuits Replace leaking parts and top up fluid to the correct level Remove brake fluid circuit and replace Brake fluid in bad state with fresh fluid of the right type Replace master cylinder piston Master cylinder piston worn Adjust brakes System badly adjusted Fusing bulbs Voltage regulator problems Check connections Check voltage regulator and fuses
4. manual Bas N JTG RECOMMENDS e Incase of any doubt as to possible adjustments of your motorcycle please follow the instructions contained in this manual and or contact an authorised JTG dealer e Please read the information contained in this user manual and familiarise yourself with the features of your vehicle before driving it at maximum power e t is recommended to establish an initial running in period of at least 8 10 hours for the engine to bed in during this period do not drive at high speed or full throttle The first hours of use should be at moderate speed only e Fuel is highly inflammable Take care when refuelling and always stop the engine first e Before running the engine at high speed it is important to have reached an optimum operating temperature especially when starting up the motorcycle or in low temperature conditions e This motorcycle uses synthetic two stroke oil mixed with 98 octane fuel in a 1 proportion Do not use any other type of lubrication without first consulting with an authorised JTG mechanic e This motorcycle is designed to carry only one person it is not permitted to carry a passenger e For the longest possible service life keep the motorcycle maintained according to the recommendations in this manual e This vehicle has been designed for safe riding as long as the rider is equipped with the necessary safety gear Helmet body protection etc Take care and ride in a sensible manner S
5. the handlebar contains Clutch lever Horn Engine stop button Main dip beam switch and indicator switch The instrument panel is in the centre of the handlebar More information and instructions for use provided later in the manual The right hand side of the handlebar contains Brake lever Throttle ADJUSTING LEVERS AND THE HANDLEBAR Both levers must have a free play of 3 mm at the most This play must be present do not eliminate it To adjust use the adjustment nuts located on the levers To adapt the handlebar to different types of riding you can tilt it more or less by loosening the clamps that secure it to the fork When adjusted as desired tighten the bolts again starting with the bolts closest to the seat and continuing with those closest to the speedometer JTG CHECKING THE OIL LEVEL The engine holds 400 cc of transmission oil Try to keep the level between maximum and minimum levels for correct operation of the engine Do not mix oils of different types always top up with the same oil We recommend OW 75 GEAR TRANS type oil JITG Oil change There is a plug at the bottom of the sump for emptying the oil and another plug at the top for filling To change the oil start up the cold engine and let it tick over for 5 minutes This will heat the oil enough for changing Then place a tray under the engine and remove the oil plug Let all the oil drain out and clean
6. TE TABLE OF CONTENTS Description of parts Technical datasheet Vehicle information Starting and stopping the engine The choke Gear change Fuel tap Fuel tank Tyres Brakes Steering lock Side stand Handlebar and instrument panel Adjusting levers and the handlebar Checking the oil level Air filter 11 12 12 13 13 14 15 16 17 17 18 19 19 20 Sparkplug Cooling system Carburettor Adjusting the tick over Reed valve box Transmission chain Suspension Swing arm Maintaining the motorcycle Speedometer Torque values Storage Maintenance operations Homologation Troubleshooting 21 22 23 24 25 25 26 27 28 29 33 34 35 39 40 DESCRIPTION OF PARTS 1 Clutch lever 2 Indicator horn and stop buttons 3 Brake lever 4 Accelerator 5 Radiator cap 6 Fuel tank cap 7 Starting pedal 8 Fuel tank 9 Radiator 10 Radiator drainage bolt 11 Sump oil level peep hole 12 Rear brake pedal 13 Engine breather 14 Fuel tap 15 Reed valve 16 Transmission chain 18 Gear change pedal JTG 19 Front fork 25 Front mudguard 31 Rear sprocket 20 Spark plug 26 Front brake caliper 32 Speedometer 21 Silencer 27 Ignition cover 33 Front suspension adjustment 22 Swing arm 28 Air filter cover 34 Footrests 23 Exhaust pipe 29 Carburettor 35 Rear mudguard 24 Water pump 30 Centre stand 6 34 30 35 N STG TECHNICAL DATASHEET Type Double beam with lateral su
7. e engine JTG The carburettor should be checked after a certain time cleaning it and drying with compressed air so as to improve its performance CARBURETTOR Check the height of the float that maintains the level of petrol in the carburettor and adjust it so it remains at 17mm within the specified margins When manipulating the carburettor and adjacent parts there may be traces of fuel that must first be drained This fuel is inflammable and toxic take care JTG Air fuel mixture An optimum petrol air mixture will enable you to obtain the maximum performance from your engine For this purpose the amount of air and fuel entering the carburettor must be adjusted A good way discover the quality of the mixture is to inspect the spark plug If the spark plug has a light brown colour the mixture is correct if it is black there is an excess of fuel and if it is white there is an excess of air in both cases the mixture entering the engine is incorrect To adjust the amount of petrol reaching the engine you can modify the position of the main jet which has a scale where the larger numbers indicate greater passage of petrol You can also control the mixture with the air adjustment screw Screwing in to enrich the mixture and vice versa ADJUSTING THE TICK OVER There are two screws on the carburettor that can be used to adjust the tick over The air adjustment screw and the tick over screw that will enable you t
8. easured when the tyre is cold JTG BRAKES You should regularly check the state of the front and rear brake pads as well as the brake fluid level For your safety as well as precise and effective riding do not use the motorcycle with excessively worn brake pads or brake fluid below the minimum level If the brake pedal has a spongy feel there may be air in the hydraulic system and it will need to be bled lt The brake fluid level can be checked through the peephole on the front master cylinder and the fluid reservoir of the rear master cylinder The level must reach the middle fill both reservoirs if necessary Use D O T 4 brake fluid There are bleed nipples on both circuits in order to eliminate air bubbles that could have entered the system after any work has been carried out The brake pedal must have some free play JTC STEERING LOCK SIDE STAND The steering lock is located under the lower front fork triple clamp To lock the steering insert the key and turn the handlebars right as far as they will go then press and turn the key anti clockwise The side stand is on the right of the motorcycle secured to To unlock insert the key and turn clockwise the chassis with a spring Move the side stand out as far as it will go in order to rest the motorcycle on it when stationary Never drive with the side stand unfolded N JTG HANDLEBAR AND INSTRUMENT PANEL P The left hand side of
9. g period of time the following operations are recommended before storage e Clean the whole vehicle e Lubricate or grease the components that need it e Empty the fuel tank Take care with the fuel which is inflammable and toxic e Empty the sump removing the old transmission oil and refilling with new oil If the engine is cold it is recommended to start up and leave running for a few minutes to warm up the oil and favour draining e Cover the exhaust with a plastic bag protecting it form the elements e Any unpainted metal parts that could get rusty should be coated with oil e Avoid the tyres touching the ground by placing a piece of cardboard or similar material under them e Protect the motorcycle as much as possible form dust and dirt by covering it with a plastic or canvas sheet When putting the motorcycle back into service first e Remove the plastic protection used e Check the oil and lubrication of components e Check the spark plug e Adjust type pressure to the recommended value e Fill the petrol tank MAINTENANCE OPERATIONS NOTE Bear in mind that a clean motorcycle will facilitate inspection and detection of faults and wear COMPONENT CHECK ADJUST REPLACE CLEAN LUBRICATE Rear shock absorber Annually Front fork suspension oil ee re 3h 6h i oe time it is Whenever Brake adjustment used necessa sary Spark plug Oo ee e y re Every time it is Every time it is Whenever it Swinging a
10. m in this manual e g for ordering new keys if you lose them Pd We recommend you take note of the serial number and identification data of your motorcycle for use in case of theft or to order spare parts 1 MANUFACTURER S IDENTIFICATION PLATE 2 CHASSIS NUMBER 3 KEY CODE Supplied with the keys JTG STARTING AND STOPPING THE ENGINE To start the motorcycle first make sure that the fuel tap is open and that the gearbox is in neutral or if not that the clutch lever is pulled in Then push the starting pedal located on the right hand side of the motorcycle It will also be necessary to use the choke when starting from cold To stop the engine select neutral and press the stop button on the handlebar THE CHOKE Use the choke when the engine is cold to start without causing damage to the engine This device when used properly will avoid excessive wear and mechanical damage when starting in cold temperature To activate it lift the black lever on the carburettor A i ee 4 4 GEAR CHANGE The gear change is controlled by a pedal on the left hand side of the vehicle the sequence is as indicated in the illustration At the same time as you change gears you must disengage the clutch by pulling in the clutch lever on the left hand side of the handlebar The gearbox is sequential i e to change from 2 to 4 gear you must first go through 3 gear JTG FUEL TAP The fuel tap is u
11. nder the fuel tank For the fuel to flow the tap must be in the ON position For reserve select the RES position and to shut of the flow leave the tap lever in an intermediate position between ON and RES N JTG FUEL TANK This motorcycle s fuel tank is built into the chassis more specifically the upper part of the chassis It holds 2 7 litres of fuel which should be lead free petrol with two stroke oil in the proportions specified on the technical datasheet The tank cap is at the top of the tank Petrol minimum octane rating 98 octanes Important Do not mix vegetable and mineral oil Respect the specified levels and proportions for correct combustion For a homogeneous mix first pour the oil into a container and add some petrol shake and then add the mixture to the rest of the petrol Avoid mixing at low temperature as this will make the operation more difficult JTG TYRES TYRES Front wheel 2 75 x 21 TRIAL Rear wheel 4 00 x 18 TRIAL RECOMMENDED TYRE PRESSURES Front wheel 0 45 bar 0 42 bar for competition Rear wheel 0 35 bar 0 3 bar for competition Tyres in good state will significantly contribute to y e y When riding on low adherence terrain you can reduce the pressure slightly in order to favour adhesion and vice versa your safety and will guarantee better driving behaviour Make sure the pressures are correct at all times and check for wear Pressure should be m
12. nds the active digits will begin to flash In this order hours minutes seconds and in display mode which can be modified with the UP and DOWN buttons and select with the MODE button In time configuration mode if 20 seconds pass without pressing any button or if the vehicle begins to move the system will return to standard operational mode saving the modified configuration STEG Trip Average speed and Automatic Chronometer functions TR1 A1 and S1 These functions indicate the partial distance covered average time and the time the vehicle has been on the current trip They are activated automatically and are displayed on the screen with the indicators TR1 A1 and S1 respectively displaying the distance covered in km speed in km h and time in hours minutes and seconds by default Manual Stopwatch function LAP This function enables you to activate or deactivate a stopwatch manually either if the vehicle is stationary or in movement To activate the stopwatch press the UP button on the screen displayed below and to deactivate press the UP button again To delete the average time press the DOWN button 080 158 59 For more information on the rest of functions of the system go to http www jotagas com TORQUE VALUES ELEMENTSFASTENED Nm Upper shock absorber fastener Spark plug Sump fasteners Sumpdrainplug 2 ITC N STORAGE If it is necessary to store the motorcycle for a lon
13. not forget that the radiator can get very hot when manipulating take care and let it cool down after switching off the engine Always use coolant 30 C for alloy engines when topping up the radiator Regularly check the radiator inlet and outlet tubes for impacts cracks or leaks that could compromise the cooling Also check the radiator alloy fins For correct operation of the engine make sure the level of the coolant is correct You can top up the radiator tank preferably with the recommended coolant through the cap at the top Do this with the engine cold and the motorcycle upright first open the cap partially by turning anti clockwise and let any steam escape Then open the cap completely and top up the fluid if necessary until it is just below the rubber The coolant supplied in the factory is a permanent mix of ethylene glycol diluted in distilled water at 50 concentration and with anticorrosion additives It is recommended to change the fluid after some time in use and bleed the system Pay attention to any abnormal colour of the fluid white particles corroded aluminium brown particles corroded steel parts and be respectful with the environment do not pour the fluid into inadequate places There is a thermal switch at the bottom of the radiator its job is to control the temperature of the liquid in the cooling circuit This device should be in correct working order in order to avoid possible damage to th
14. o change the speed of operation if necessary JTG REED VALVE BOX TRANSMISSION CHAIN Admission is through a reed valve the state of which has a significant influence on the performance of the engine Whenever the carburettor is removed for cleaning make sure the reed valves are not worn and if so replace the box with a new one JTG Correct tension of the chain should allow a play of approximately 10 15 mm in the area between the frame and the tensioner To tension the chain first loosen the rear wheel axle nut and then adjust the chain using the tensioner adjustment bolts which are in the swing arm When adjusted retighten the rear axle nut paying special attention to the alignment of the chain ensuring that it is not twisted A Take care with this adjustment A misaligned rear wheel axle or with the nut loose could cause an accident Keep the chain lubricated for optimum service life preferably using viscous oil for longer life SUSPENSION The front fork can be adjusted with the bolts at the top of the fork Turning the bolt on the left hand fork tube you can adjust the compression and it you turn the bolt on the right hand tube you adjust the extension Choose the best option according to your needs always bearing in mind that the left and right hand cylinders must be adjusted to the same level and perfectly aligned The preload of the spring can be adjusted by turning the castellated nut a
15. orised workshop Bear in mind that unskilled manipulation of the ITT motorcycle can be dangerous for you and or possibly render the guarantee void PROBLEM POSSIBLE CAUSES ACTIONS The engine will not start Dirty spark plug Clean and dry the spark plug or Engine flooded change it Open the throttle fully and kick the starter pedal 5 to 10 times and then Fuel badly mixed start the engine Check for obstruction in the petrol tank tubes and air filter The motorcycle starts well and then Incorrect air supply engine flooded Close the choke check the fuel pipes stops Insufficient petrol Fillthe fuel tank Engine excessively hot Low level of coolant Add coolant check for possible leaks Clean the radiator fins Radiator dirty or obstructed Engine runs erratically Problems with the spark plug and or Check the state of both plug cap Fault in the ignition rotor Change the rotor Water in the fuel Empty the tank and refill with new petrol Engine makes strange noises Ignition problems Take motorcycle to an authorised Overheated engine workshop Stop the engine and check the state of the cooling and exhaust systems Engine lacks power Admission problems Clean the fuel admission system and air filter Exhaust system problems Check for leaks in the system and clean or replace the silencer fibre Carburettor jets dirty Remove the carburettor and clean Damaged c
16. rankshaft bearings them Clutch slipping Replace the bearings Check its adjustments Take bike to a specialised workshop Accelerator cable incorrectly adjusted Check accelerator adjustment Main jet too high Check the main jet Explosions in the exhaust Carbon deposits in the combustion Clean the combustion chamber chamber Incorrect type of fuel Empty fuel tank and refill with correct type of fuel Spark plug in bad condition or wrong Replace spark plug with correct type type Check state of gaskets and replace if Exhaust system gaskets damaged necessary Clutch not working correctly No play in the clutch lever Take bike to a specialised workshop Clutch worn ITS eN ieee sapecsised wertshop Take bike to a specialised workshop gearbox systems Abnormal noises Worn or badly adjusted chain Adjust or change chain Rear sprocket teeth worn Change rear sprocket Chain needs lubrication Apply appropriate chain lubricant Take bike to a specialised workshop Badly aligned rear wheel Add fork oil to the specified level Lack of oil in the front fork Replace front fork spring Problems with the front fork springs Replace brake disc Worn brake disc Refit pads or replace Brake pads glazed or badly fitted Unstable ride Steering shaft nut too tight Loosen the steering nut a little Steering bearings worn or damaged Replace bearings
17. rm and connecting rods If damaged used used is cleaned a Every time it is Whenever Every time itis Whenever it Transmission chain If damaged used necessary used is cleaned Every time it is Whenever Whenever Whenever it Throttle cable and twist grip y If damaged used necessary necessary is cleaned Every time it is used Wh E time it i necessary used Every time it is used Wh necessary Steeringbearing damaged Jo o o y Pistonbearins damaged Wheelbearing damaged Enginebearings damaged E time it Rear sprocket 30h First Sh If damaged vie Aaa is cleaned Cylinder head and cylinder o 6h aly l y O E i Wh used necessary E i E Brake discs ord G ALE First 5h If damaged eae ANA pS used uses Clutch plates 00 damaged po utch damaged Every time In case of a Wheel silencer clearance y used fall po y Eae HP Silencer fibre ON a mee Every time Every time Every time it Air filter y If damaged J used used is cleaned steerihanla Every time Whenever Bia used necessary Whenever Every time it necessary is cleaned bs ae Wh necessary E ti Every time Every time it General lubrication ie ll y y used used is cleaned Every time used Every time Every time T If damaged Ai used 0 ime used an Wh necessary Starter pedal and gear change pedal ee po is cleaned Brake master cylinder piston and dust Se ee ee Chain guide slipper If damaged Ifdamaged
18. s always visible regardless of the status of the vehicle stationary or in movement The default configuration indicates Km h 03848 68 speed 130 If the speed of the vehicle exceeds 110 km h for more than 20 consecutive seconds the status on the right hand illustration will be displayed flashing This signal will continue until the speed of the vehicle drops below 110 km h for at least 10 consecutive seconds ODO function This information can only be seen by pushing the MODE button regardless of whether the vehicle is Stationary or in movement The predetermined configuration indicates Km and each Km is permanently stored in the in the memory H function This function indicates the hours the vehicle has been in Operation and can be seen by pressing the MODE button regardless of whether the vehicle is stationary or in movement The counter associated with this function only works when the vehicle is in movement on receiving the first impulse from the speed sensor and it stops 3s after receiving the last impulse from the sensor ae 66 Ban Clock function CLK This function indicates the current time in hh mm ss format The clock remains active even when Sleep Mode is activated 90158 8 The time can only be set when the vehicle is Stationary pressing the MODE button several times until the display screen is as illustrated above When the CLK mode is displayed pressing the MODE button for a few seco
19. spension system and built in fuel tank Front 2 75 x 21 44 160 kg L Rear 4 00 x 18 52 200 kg L Front TECH Hydraulic telescopic fork COM EX 039 mm 175 mm travel Rear V3 progressive system with OLLE mono adjustable shock absorber 175mm travel Front Disc 2185 mm 4 piston caliper Rear Disc 150 mm 2 piston caliper Type Two stroke single cylinder reed valve admission directly to the engine block liquid cooled Cubic capacity 301 58 cc Piston diameter 80 mm Stroke 60 mm Carburettor DELLORTO PHBL26 Lubrication system 1 mixture 1 100 Ignition Digital CDI HIDRIA Spark plug NGK BPMR6A Generator 12V 110W N JTG Type 5 speed with hydraulically operated clutch Secondary transmission Chain Gear ratios 1 3 000 33 11 2 2 571 36 14 3 2 187 35 16 4 1 444 26 18 5 0 889 24 27 Primary reduction 2 778 75 27 Final reduction 4 40 10 Total ratio 5 gear 9 879 Transmission oil 400 cc type GEAR TRANS OW75 Overall height 1160 mm Overall width 833 mm Seat height 650 mm Wheelbase 1180 mm Fuel capacity 2 7 litres Dry weight 64 kg VEHICLE INFORMATION MANUFACTURER S IDENTIFICATION PLATE Under the fuel tank This plate contains information regarding vehicle certification take note of this for easy identification of your vehicle when needed O O SERIAL NUMBER AND KEY CODE These numbers identify your motorcycle and the steering lock take note of the
20. t the base of the shock absorber It is also possible to adjust the hydraulic brake of the shock absorber with a bolt at the top This bolt must be in the middle of its travel in normal adjustment SWING ARM For correct maintenance of the rear suspension system and swing arm it must be regularly dismantled for cleaning checking and lubricating the internal bearings as well as adjustment and lubrication of the chain Make sure that all the parts are in perfect state and replace any worn components if necessary ITT Doar JIE MAINTAINING THE MOTORCYCLE The greater the care given to the motorcycle the longer its service life will be and the better it will perform Check all the elements listed below and keep them clean and lubricated for optimum service LEVER ARTICULATIONS REAR BRAKE PEDAL GEAR LEVER FOOTRESTS AND SIDE STAND STARTER PEDAL THROTTLE STEERING COLUMN TRANSMISSION CHAIN AND SWING ARM ARTICULATIONS CHAIN TENSIONER JTG These are the most important features of the control panel and speedometer fitted to your motorcycle SPEEDOMETER LEP TRE Wiles WS SPED TIT TIT N a IN EK i JT G These are its features 300 km h 186 Mh km h Moh Eer 500m The basic functions Always visible and cannot be deselected from the setup menu of the panel are Current speed SPEED Total distance covered ODO Total time of vehicle operation H SPEED function This information i
21. the plug removing any possible metal filings When it is clean refit and fill with new oil through the upper filling plug orifice until it reaches the correct level in the peep hole AIR FILTER After removing the filter it can be cleaned using a specific degreaser then washed with water and detergent let the filter dry and then coat it with special air filter oil It is recommended to check the state of the air filter regularly to avoid problems due to particles in the admission Make sure you clean it in a ventilated place without sparks nearby and do not use petrol for cleaning as this could cause an explosion The location of hatch on the left hand side of the motorcycle offers easy access to the air filter Take care with the filter foam when dismantling as it is easily damaged Access the air filter through the hatch and dismantle its securing elements Remove the support cage with care so as not to damage the foam Clean it in a container and dry with a lint free cloth When it is clean it can be slightly lubricated with special oil for air filters before replacing in its housing SPARK PLUG The spark plug fitted in the factory is as defined in the specifications datasheet Tighten to 11 Nm Ay For correct maintenance of the engine it is recommended to clean the spark plug electrode with compressed air ensuring that the gap is approximately 0 6 0 7 mm JTG COOLING SYSTEM Do
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