Eddy Current Brake Installation Guide For Motorcycle Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual is furnished under license and may only be used
or copied in accordance with the terms of such license. This manual is furnished for
informational use only, is subject to change without notice, and should not be construed
as a commitment by Dynojet. Dynojet assumes no responsibility or liability for any error
or inaccuracies that may appear in this manual. Except as permitted by such license, no
part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, recording, or otherwise, without the prior
written permission of Dynojet.
The Dynojet logo is a trademark of Dynojet Research, Inc.
Any trademarks, trade names, service marks, or service names owned or registered by any
other company and used in this guide are the property of their respective companies.
Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89031, USA.
This document provides instructions for installing the Eddy Current Brake (retarder)
optional hardware to Dynojet’s Model 150 and 200 Motorcycle Dynamometers. To
ensure safety and accuracy in the procedures, perform the procedures as they are
described.
Document Part Number: 98226100
Versio n 8
Last Updated: 03-29-02
CONVENTIONS
The conventions used in this manual are designed to protect both the user and the
equipment.
example of conventiondescription
The Caution icon indicates a potential hazard to the
dynamometer equipment. Follow all procedures
exactly as they are described and use care when
performing all procedures.
The Warning icon indicates potential harm to the
person performing a procedure and/or the
dynamometer equipment.
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write
to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89031.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, 3D visualizations, and press releases
about our latest product line.
The following table lists all of the parts included in the Eddy Current Brake
Installation kit. Check your kit against the parts listed to make sure you have received
all of the parts. If any part is missing, contact Dynojet Technical Support.
part numberdescriptionquantity
1971041304" Zip Tie4
25111310Clamp, Retarder Hood2
61229101Hood Assembly, M/C Retarder1
62992001
Or
62992002
29250001Mod-Key, 1/2 x 7/16 x 2"1
29250002Key, 3/8 x 3/8 x 2" (installed)1
Retarder-Generic
Or
Retarder-Generic, European
1
32431332Male Coupler, mounted on eddy current brake
32431333Female Coupler Assembly with four set screws
36488101Nut, 3/8-16, Hex, W/Tlok5
36581270Bolt, 3/8-16 x 3/4", W/Tlok28
36581670Bolt, 3/8-16 x 1", W/Tlok (for right side installation)4
43312200Grommet, 1-5/8OD x 1-3/8ID (one is installed)2
This section describes how to unpack the eddy current brake and remove the hood
from your dyno.
UNPACKINGTHE EDDY CURRENT BRAKE
1Remove the top and sides of the crate.
2If you ordered a hood upgrade, remove the new hood from the crate.
3Remove the four bolts securing the eddy current brake cover and set aside.
4Remove the two bolts securing the hood clamps to the brake and set aside.
5Remove the hardware box from the crate and verify the hardware box contents.
Refer to the parts list on page 1-2.
brake cover
Preparation
hood clamps
Figure 1-1: Remove the Brake Cover and Hood Keepers
Vers ion 8Eddy Current Brake Installation Guide
1-3
CHAPTER 1
Preparation
6Remove the eddy current brake from the crate.
Note: Dynojet recommends using a continuous nylon loop style strap to lift the
eddy current brake from the crate.
6aRemove the bolts securing the eddy current brake to the crate.
6bPlace the nylon loop strap around the top of the brake frame making sure it
crosses as shown in Figure 1-2.
6cUsing the nylon loop strap, remove the eddy current brake from the crate
and place it near the dyno.
Figure 1-2: Remove the Eddy Current Brake from the Crate
REMOVINGTHE DYNO HOOD
1Remove the four bolts securing the hood to the dyno and set aside. Prop up the
hood.
2If present, disconnect the wires to the key switch.
3Remove the hood from the dyno and set aside.
4Disconnect all battery wires.
This section describes how to remove both the air brake and the manual brake, the
brake caliper assembly, and the rotor.
If you are mounting the eddy current brake on the right side of your dyno, you do not
need to remove the air or manual brake.
Note: Safety requirements of your local country may require that both brakes are
installed. Be sure to follow the safety requirements specific to your country.
REMOVINGTHE AIR BRAKE
1Disconnect all air lines from the dyno.
2Disconnect the brake electrical wires.
• Model 150 dynos: Disconnect the brake wires from the electrical block
mounted on the center of the dyno frame. Refer to the DynoWare EX+
Upgrade manual for more information.
air brake
solenoid wires
loosen screws
Figure 1-4: Remove the Air Brake Solenoid Wires
• Upgraded Model 150/Model 200 dynos: Disconnect the brake wires from
the Breakout board located on the side of the dyno.
brake wires
Figure 1-5: Remove the Brake Wires from the Breakout Board
Vers ion 8Eddy Current Brake Installation Guide
1-5
CHAPTER 1
Air Brake and Manual Brake Removal
3Remove the jam nuts, adjuster nuts, retainers, and springs.
The springs are compressed. Use caution when removing the springs.
4Disconnect the brake line from the master cylinder to the caliper.
Note: Make sure you have disconnected all air lines and released the tension in
the springs before disconnecting the brake line.
cut away view of dyno
side panel
spring
adjuster nut
jam nut
retainer
Figure 1-6: Air Brake—Remove the Springs
5Remove the two bolts securing the master cylinder to the air cylinder using a
3/16-inch allen wrench. Remove the master cylinder.
master cylinder
bolts
1-6
Eddy Current Brake Installation Guide
Figure 1-7: Air Brake—Remove the Master Cylinder
EDDY CURRENT BRAKE INSTALLATION
Air Brake and Manual Brake Removal
6Remove the bolt securing the spring bolt mounting plate.
7Remove the mounting plate and the air cylinder from the dyno frame.
air cylinder
Figure 1-8: Air Brake—Remove the Air Cylinder
REMOVINGTHE MANUAL BRAKE
1Disconnect the brake line from the master cylinder to the caliper.
2Remove the four bolts, lock washers, and flat washers that secure the master
cylinder and foot pedal.
The bolts run from the inside, through the master cylinder, and into the foot
pedal mounting plate.
foot pedal
bolt
mounting plate
master cylinder
Figure 1-9: Remove the Manual Brake
Vers ion 8Eddy Current Brake Installation Guide
1-7
CHAPTER 1
Air Brake and Manual Brake Removal
REMOVINGTHE BRAKE CALIPER ASSEMBLY
1Remove the four bolts and washers that secure the caliper assembly.
2Loosen the brake pads and remove the assembly.
Note: Do not put the bolts back into the dyno frame. The holes will be used to
mount the eddy current brake to the dyno.
3Loosen the set screw above the keyway in the drum axle using a 3/16-inch allen
wrench.
4Remove the three 5/16-inch bolts in the lock collar and insert these bolts in the
three threaded holes in the lock collar. Tighten the bolts until the collar comes
loose.
5Slide the rotor and lock collar off the drum axle and remove the key.
caliper assembly
lock collar
Figure 1-10: Remove the Brake Caliper Assembly
key way
1-8
Eddy Current Brake Installation Guide
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