Dynojet 200iX, 250iX Installation Manual

©2010-2016 Dynojet Research, Inc. All Rights Reserved.

#

RECORD

Installation Guide For Above Ground Model 200iX and 250iX DynoWare RT 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 89081, USA.

Printed in USA.

Part Number: 98200077 Version 2 (07/2016)

Dynamometer Number: ____________________________________________________

iX Dynamometer Number: _________________________________________________

iXW Dynamometer Number: _________________________________________________

Eddy Current Brake
(Retarder) Number:_________________________________________________________

T

ABLE OF

C

ONTENTS

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Chapter 1 Specifications and Operating Requirements

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Your Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Drill and Drill Bit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Ground Hook Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

DynoWare RT Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Main Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Chapter 2 Installation

Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Routing the Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Installing the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

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Secure the Dyno and Brake Module to the Floor . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Remove the Dyno Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

iX Drum Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Removing the Items from Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Installing the iX Drum Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Installing the Bulkheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Identifying the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Installing the DynoWare RT Main Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Routing the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Routing the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . . . . . . . . . 2-38

Side and Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Installing the iX Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Fan Arm Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Trike Carriage Adapter and Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Installing the Trike Carriage Adapter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Installing the Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Monitor Support and Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Control Panel and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

High Pressure Blower Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Trike Carriage Adapter Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Zip Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Ground Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Ramp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Chapter 3 Accessories

Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Routing the Air Brake Cables and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

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Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Air Fuel Ratio Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Installing the Extension Support and Trike Carriage Adapter Assembly . . . . . . 3-18

Installing the Extended Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Removing the Hand Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Installing the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

TABLE OF CONTENTS

Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Chapter 4 Control Panel Interface Operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Basic CPI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Using the Emergency Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Using the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Understanding Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Using the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Using the Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Using the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Power Distribution Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Main Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

High Pressure Blower Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Maintaining and Troubleshooting the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . 4-10

Replacing the Eddy Current Brake Driver Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Troubleshooting CPI Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Chapter 5 Basic Dyno Operation

Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Connecting The Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Grounding the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Using the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

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Appendix A Red Head Anchor Installation

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Appendix B Power Requirements and Installation

Power Requirements and Installation—North America, Japan,
and Locations Using 60 Hz Power

Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Power Requirements and Installation—Excluding North America and Japan B-5

Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Appendix C EEC Kit Installation

EEC Finger Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Removing the Drum Module Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Installing the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Adjusting the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Installing the Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Appendix D Folding Ramp Installation

Ramp Installation—Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Removing the Ramp from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Installing the Ramp on the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7

Ramp Installation—iX Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10

Appendix E Above Ground iXW Installation

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Dynamometer Specifications—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . E-2

Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Above Ground iXW Upgrade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Removing the Items from Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Installing the Above Ground iXW Drum Module . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8

Installing the Bulkheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11

Continue Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13

Side and Top Covers—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . . . . . . . E-14

Installing the iXW Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-16

Continue Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-17

Ground Hook Installation—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . . . E-18

TABLE OF CONTENTS

Appendix F Torque Values

Standard Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

Grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

Grade 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

Grade 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

v

W

CAUTION

ARNINGS

Disclaimers

Dynojet Research, Inc. (Dynojet) makes no representation or warranties with respect to the contents
hereof and specifically disclaims any implied warranties of merchantability for any particular purpose.

Dynojet reserves the right to revise this publication and to make changes from time to time in the
content hereof without obligation of Dynojet to notify any person of such revision or changes.

Dynojet is not responsible for false operation due to unexpected dynamometer operation such as may
be caused by static, software bugs, hardware failure, etc.

Dynojet is not responsible for damage resulting from improper installation of the dynamometer or
from improper service rendered to the dynamometer. Dynojet is not responsible for damage incurred
due to alteration of the dynamometer or components, use of unapproved parts, or abuse to the
dynamometer.

Do not connect or disconnect cables or components on the dynamometer with the power on.
Always wear protective clothing, ear protection, and eye protection (goggles, safety glasses) when using

and servicing the dynamometer.

Equipment Power Requirements

The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect
voltage will void the dynamometer warranty. Installation may require a licensed electrician.

Potentially Lethal Voltages

Components attached to and within the dynamometer operate with potentially lethal voltages. To
provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power
source before servicing electrical components or wiring. Disconnect all power cords before servicing
electrical components for the greatest assurance of safety.

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

vii

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

viii

WARN ING S

Electrostatic Discharge Precautions

CAUTION

Electrostatic Discharge

Electrostatic Discharge (ESD), or static shock, can damage electronic components within the
dynamometer. The damage may occur at the time of an ESD occurrence, or the shock may degrade the
component, resulting in a premature component failure later. To avoid ESD damage, always practice
good ESD control precautions when servicing the dynamometer. Dynojet designs its dynamometers
to be very tolerant of static shocks by the users, but the electronics are vulnerable when the electronics
are exposed. ESD occurs as a result of a difference of potential between two o bjects when the two objects
touch. Damage occurs as a result of the energy released when the discharge (touch) occurs. The
difference of potential can accumulate by as simple an action as a user moving across carpet or a seat.
If that person’s energy is discharged directly to the electronics, the electronics can be damaged .

Precautions

To protect against ESD damage, you must eliminate the di ffer ence of pote nt ial befo re the el ect r oni cs
are handled. Touch the chassis of the dynamometer before touching any of the electronics. By touching
the chassis, you discharge any static shocks to the chassis instead of to the electronics.

If you are holding a circuit board or dynamometer component in your hand when you approach the
machine, touch the chassis of the dynamometer with your hand before installing the circuit board or
component.

When handling a circuit board or component to someone, touch that person with your hand first, then
hand them the component.

Always carry circuit boards in anti-static bags when the boards are exposed (removed from the
dynamometer).

Battery Fire and Explosion Hazards

There is a danger of explosion if the battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Discard used batteries according to the
manufacturer’s instructions.

Automotive Batteries

In operation, batteries generate and release flammable hydrogen gas. They must always be assumed
to contain this gas which, if ignited by burning cigarette, naked flame or spark, may cause battery
explosion with dispersion of casing fragments and corrosive liquid electrolyte. Carefully follow
manufacturer's instructions for installation and service. Keep away all sources of gas ignition and do
not allow metallic articles to simultaneously contact the negative and positive terminals of a battery.

Do not allow the positive and negative terminals to short-circuit. The dynamometer chassis is tied to
the negative side of the battery. Do not short between the positive battery terminal or the starter
connections to the chassis. In addition, make sure metal tools such as screw drivers, wrenches, and
torque wrenches do not come in contact with the negative and positi ve terminals of the battery. Short
circuiting the terminals of the battery can cause burn injuries, damage to the dynamometer, or trigger
explosions.

Charging

Batteries being charged will generate and release flammable hydrogen gas. Charging space should be
ventilated. Keep battery vent caps in position. Prohibit smoking and avoid creation of flames and sparks
nearby.

Wear protective clothing, eye and face protection, when charging or handling batteries.

WARN ING S

CAUTION

Grounding Requirements

Always ground the vehicle to the dynamometer. Never operate the dynamometer without properly
grounding the vehicle to the dyno.

Other Potential Hazards

The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for
disconnect before service.

The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.

Any dyno room design must incorporate sufficient exhaust extraction.
Always wear proper ear and eye protection when operating the dynamometer.
Never operate the dynamometer with the covers removed.
Never stand behind the dynamometer when in operation.
Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems

before proceeding.
Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken.
Verify brake operation before beginning any dynamometer testing.
Verify the vehicle is properly secured to the dynamometer.
Verify the vehicle is properly grounded to the dynamometer.
Never operate the blowers without the guards installed.
Exercise care with any dynamometer testing; portions of the dynamometer and vehicle may become

hot.
As with any equipment using electricity and having moving parts, there are potential hazards. To use

this dynamometer safely, the operator should become familiar with the instructions for operation of
the dynamometer and always exercise care when using it.

Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically
recommended in published user-repair instructions that you understand and have the skills to carry
out.

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

ix

CHAPTER 1

S

PECIFICATIONS AND

O

PERATING

R

EQUIREMENTS

Thank you for purchasing Dynojet’s Above Ground Model 200iX/250iX Motorcycle
Dynamometer. Dynojet’s software and dynamometers will give you the power to get
the maximum performance out of vehicles you evaluate. Whether you are new to the
benefits of a chassis dynamometer or an experienced performance leader, the
repeatability and diagnostic tools of Power Core software and a Dynojet dynamometer
will give you the professional results you are looking for.

This document provides instructions for installing the above ground motorcycle
dynamometer (dyno) along with the kart upgrade. This document will walk you
through operating requirements, installation, accessories, and basic dyno operation.
To ensure safety and accuracy in the procedures, perform the procedures as they are
described.

Document Part Number: 98200077
Version 2
Last Updated: 07-25-2016

This chapter is divided into the following categories:

• Introduction, page 1-2

• Dynamometer Specifications and Requirements, page 1-5

• DynoWare RT Electronics, page 1-11

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-1

CHAPTER 1

Introduction

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-2

INTRODUCTION

Before installing your dyno, please take a moment to read this guide for installation
instructions, dyno features, and other important information.

This guide is designed to be a reference tool in your everyday work and includes the
following chapters and information:

SPECIFICATIONS AND OPERATING REQUIREMENTS

This chapter describes the requirements and specifications for the dyno.

INSTALLATION

This chapter describes the procedures for installing the dyno.

ACCESSORIES

This chapter lists each dyno accessory alphabetically and describes the procedures for
installing and using the accessory.

CONTROL PANEL INTERFACE OPERATION

This chapter describes the Control Panel Interface (CPI) operating procedures.

BASIC DYNO OPERATION

This chapter describes basic dyno operating procedures.

RED HEAD INSTALLATION

This appendix describes the procedures for installing the Red Head anchors.

POWER REQUIREMENTS

This appendix describes the power requirements and installation instructions for the
dyno.

EEC FINGER GUARD & DOOR SAFETY SWITCH KIT

This appendix describes the procedures for installing the EEC finger guards and door
safety switch.

FOLDING RAMP INSTALLATION

This appendix describes the procedures for installing the folding ramp assemblies for
the dyno and iX upgrade.

ABOVE GROUND IXW INSTALLATION

This appendix describes the procedures for installing the above ground iXW upgrade
kit.

TORQUE VALUES

This appendix describes standard and metric torque values.

SPECIFICATIONS AND OPERATING REQUIREMENTS

Introduction

CONVENTIONS USED IN THIS MANUAL

CAUTION

#

RECORD

The conventions used in this manual are designed to protect both the user and the
equipment.

example of convention description

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.

The Record # icon reminds you to record your
dynamometer and/or eddy current brake (retarder)
number on the inside cover of this manual.

Bold Highlights items you can select on in the software



interface, including buttons and menus.
The arrow indicates a menu choice. For example,

“select

File Open” means “select the File menu,

then select the

Open choice on the File menu.”

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 89081.

Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, and press releases about our latest
product lines.

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

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CHAPTER 1

Introduction

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-4

YOUR DYNO ROOM

This section is not meant to imply that a dyno room is essential to repeatable results
on a Dynojet dynamometer. However, a dyno room with an engine cooling intake fan,
exhaust extraction, and noise reduction capabilities can add a new dimension to your
shop.

A proper dyno room design will help to ensure repeatable, accurate runs. A good dyno
room should do the following:

• minimize noise

• provide a controlled environment for testing

• provide a view window (safety glass) for customers

• be designed with safety in mind

Intake Air Fan—After building your dyno room, you will need to supply an intake air
fan. The intake air fan supplies air to cool the bike’s engine while supplying fresh
oxygen for you and your bike to breathe. It is a common misconception that you
cannot tune a bike without a large fan simulating exact road conditions; however, a
good cooling fan is the only requirement for consistent diagnostics and tuning. The
installed fan should be 5200 CFM.

Equalizer Box—If the air flow rate coming into the dyno room is greater than the air
flow rate leaving the dyno room, the room will become pressurized. A pressurized
dyno room will make measured power misleading. To compensate, you need an
equalizer box. The equalizer box is a baffled (to reduce noise) vent to the outside of
your dyno room. The size of the equalizer box is dependent on the size of your dyno
room and the size of your fans.

Exhaust Extraction—An exhaust fan is needed to remove exhaust gasses, especially
carbon monoxide, from the dyno room. Carbon monoxide is potentially lethal to
people if not removed from the room and will affect engine power when mixed with
fresh air.

Engine exhaust contains poisonous carbon monoxide gas. Breathing it
could cause death. Operate machine in well ventilated area.

Fire Suppression—Always have adequate fire suppression or fire extinguishers in your
dyno room.

Industrial Noise Control, Inc—Industrial Noise Control, Inc. offers a zinc-coated steel
room custom built to your specifications. This room meets all dyno room
requirements. The dyno room must be clean and dry with a comfortable room air
temperature above 32 degrees Fahrenheit (0 degrees Celsius), and have some system
of exhaust extraction. For more information on a dyno room, refer to your 
Pre-Installation Guide For Model 200i, 250i, 200iP, and 250iP Motorcycle
Dynamometers (P/N 98200081).

SPECIFICATIONS AND OPERATING REQUIREMENTS

Dynamometer Specifications and Requirements

DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS

The following specifications and requirements will help you set up your dyno area and
verify you have the requirements to operate your dyno safely.

BATTERY REQUIREMENTS

Your 200iX/250iX dyno is designed to carry a group 24 deep-cycle discharge series
battery for operating the starter, power carriage, and optional wheel clamp. The
typical dimensions for this seri es of batteries are 27 cm long by 17 cm wide by 23 cm
tall (10.625-inches by 6.75-inches by 9.125-inches). The mounting is flexible so a
battery that has dimensions close to this will work satisfactorily. The built-in battery
cables are configured for top-post batteries. This battery is not included with your
dyno. You will need to provide this battery. For more information on installing the
battery, refer to “Battery” on page 2-13.

CHASSIS SPECIFICATIONS

description specifications

Length

with standard carriage allow 271.78 cm (107.00 in.)
with extended carriage allow 322.58 cm (127.00 in.)
with ramp 370.84 cm (146.00 in.)

Height

to top of dyno cover 45.97 cm (18.00 in.)

Width

model 200iX 200.69 cm (79.00 in.)
model 250iX 274.32 cm (108.00 in.)

Weight

model 200i dyno/crated dyno 725 kg (1600 pounds)/771 kg (1700 pounds)
model 250i retarder module/crated 953 kg (2100 pounds)/1,089 kg (2400 pounds)
200iX/250iX drum module/crated 136 kg (300 pounds)/363 kg (800 pounds)

Drum

diameter 45.72 cm (18.00 in.)
width 50.80 cm (20.00 in.)
diameter, 200iX/250iX 45.72 cm (18.00 in.)

width, 200iX/250iX 55.88 cm (22.00 in.)
Frame structural steel
Maximum Speed 322 KPH (200 MPH)
Maximum Motorcycle Length (front of front

wheel to center of rear wheel)

standard carriage 213.00 cm (84.00 in.)

extended carriage 256.54 cm (101.00 in.)
Remote Switches remote software control

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

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CHAPTER 1

Dynamometer Specifications and Requirements

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-6

Figure 1-1: Model 250iX Dyno Dimensions

SPECIFICATIONS AND OPERATING REQUIREMENTS

Dynamometer Specifications and Requirements

iX Drum Module

Eddy Current

Brake

High Pressure

Blower

Wheel Clamp

Option

Power Carriage

Option

Monitor Support

and Tray

Model 250i Dyno

Air Brake Option

(not shown)

Air Pump Option

(not shown)

Control Panel

Trike Adapter

Assembly

Folding Ramp Option

(Dyno Module)

Folding Ramp Option

(iX Module)

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

Figure 1-2: Model 250iX Dyno with Accessories

1-7

CHAPTER 1

Dynamometer Specifications and Requirements

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-8

COMPRESSED AIR REQUIREMENTS

You will need to provide an air hose nipple (1/4-inch NPT) to connect your clean, dry
shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the
dynamometer.

The following requirements are needed when the optional air brake is included:

• regulator set to 65 psi max (450 kilopascal)

•air dryer

• shut off valve

• gauge on the regulator

• 1/4-inch NPT pipe thread connector (to attach air to the dyno)

The following requirements are needed for the on-dyno compressed air pump
assembly:

• Clean and dry air, 100 psi or greater, 5 CFM or better flow

• Fittings to hook your air system to a 3/8-inch inside diameter hose (if no air brake
is present)

• 1/4-inch NPT pipe thread compressed air connector

• optional air regulator

description minimum specifications recommended specifications

Operating System Windows 7 or later Windows 7 or later
Processor Dual Core Processor, 

Memory 4GB System Ram 8GB System Ram or more
Hard Drive 100GB or larger

Monitor/Graphics Card 1280x1024 (SXGA) resolution or

Network Adapter 1 free 10/100 Mbps

External Media CD Rom Drive CD Rom Drive
Printer Printer, if prints or needed Color printer, if prints are needed

COMPUTER SPECIFICATIONS

You will need to provide a computer system to run the Power Core software. Refer to

www.dynojet.com for the latest computer requirements.

2GHz or faster

(54MB required for program)

higher

RJ45 Ethernet Port

Intel Core i5 2.8GHz or faster

500GB or larger
(54 MB required for program)

1600x900 (WSXGA) resolution or
higher

1 free 10/100Mbps RJ45 Port on IP
Router, Wireless, or Wired and
Internet Access

SPECIFICATIONS AND OPERATING REQUIREMENTS

Dynamometer Specifications and Requirements

DRILL AND DRILL BIT REQUIREMENTS

You will need to provide a drill and drill bit capabl e of dril ling holes in concrete. Refer
to Appendix A for more information on installing Red Head Anchors.

• drill bit size: 1/2-inch

• minimum hole depth: 1 5/8-inch (41.2 mm)

ELECTRICAL REQUIREMENTS

The Model 200iX/250iX dynamometers require a 240V - 30a single-phase electrical
circuit for reliable and precise operation. No other loads should be plugged into these
circuits and these circuits should be independent of the lighting in the dyno room.
Before you plug in your dyno, you or your electrician must refer to Appendix B for
detailed information.

ENVIRONMENTAL REQUIREMENTS

description specifications

Temperature

operating min./max 10°C/50°C (50°F/122°F)
storage min./max 0°C/60°C (32°F/140°F)

Humidity 0 to 95% non condensing

FORKLIFT REQUIREMENTS

You will need to provide equipment capable of lifting a minimum of 2268 kg. 
(5000 lb.) to lift the dyno off the crate and into position in your dyno room. You will
also need a pair of straps capable of supporting 2268 kg. (5000 lb.) to attach to the
dyno. Dynojet recommends using single loop style straps.

GROUND HOOK REQUIREMENTS

You may wish to install additional ground hooks (included with your dyno) for
securing the motorcycle. The tie-down loops on the dyno covers should work for most
motorcycles. If you are running motorcycles that require a different tie-down location,
mount the ground hooks accordingly.

Note: Tie-down straps MUST pull the motorcycle forward.

Using the ground hooks as a pattern, use the hardware included with the ground hook
kit to install the Red Head anchors according to the instructions in Appendix A.

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

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CHAPTER 1

Dynamometer Specifications and Requirements

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-10

GROUNDING REQUIREMENTS

CAUTION

You will need to ground the vehicle to the dynamometer before every run using the vehicle
grounding kit P/N 76100015. Never operate the dynamometer without first grounding the
vehicle to the dynamometer. Refer to “Grounding the Vehicle” on page 5-8.

Always ground the vehicle to the dynamometer. Never operate the
dynamometer without properly grounding the vehicle to the dyno.

PHONE AND INTERNET ACCESS

Dynojet recommends you have a phone close to the dyno to call for assistance in an
emergency. You may also wish to contact Dynojet to troubleshoot your dyno.

Internet access on your computer is desirable for contacting Dynojet and downl oading
new information and updates.

TIE-DOWN STRAPS

Dynojet recommends using motorcycle tie-down straps for securing the bike on the
dyno. You will need to provide the tie-down straps.

SPECIFICATIONS AND OPERATING REQUIREMENTS

DynoWare RT Electronics

DYNOWARE RT ELECTRONICS

air fuel ratio

module

eddy current

brake driver

DynoWare RT

main module

speed pickup

The DynoWare RT electronics consists of a main module and a speed pickup. Optional
modules include the Air Fuel Ratio (AFR) module and the Eddy Current Brake (ECB)
driver. Use this section to identify the modules and connections. More detailed
information for configuring the DynoWare RT electronics can be found in the Power
Core Help.

Figure 1-3: DynoWare RT Electronics

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-11

CHAPTER 1

DynoWare RT Electronics

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-12

MAIN MODULE CONNECTIONS

1

2

1

2

12

Linx

!

C

Dynojet Research, Inc.

2191 Mendenhall Drive

N. Las Vegas, NV 89081

100-240 VAC

50-60 Hz

1.0 A

1

2

1234

Analog

Status

B

A

A

B

!

C

A description of the main module symbols and connections follows.

use this port to use this port to

RPM Inputs Connect inductive and optical

RPM inputs.

Auxiliary
Temperature

Connect to an auxiliary input
for an infrared temperature
sensor.

Communication I/O Connect to auxiliary Dynojet

Communication I/O Connect to auxiliary dyno

Communication I/O Connect to internal dyno

Drum Connect to the drum 1 and

products such as the Power
Commander, Wideband 2,
Power Vision, etc.

electronics such as the
pendant, atmospheric module,
AFR module, etc.

electronics and controllers
such as the ECB controller.

drum 2 speed inputs and
digital brake outputs.

Auxiliary Switch Connect to the brake air

pressure switch on 248 and
older 224 dynos.

Emergency Stop Connects the dyno electronics

to the emergency stop input on
the 200i/250i dynos.

Network
Connection

Connects the dyno electronics
to your computer or computer
network.

Refer to
Instructions

Do not press this button unless
instructed to do so by a Dynojet
Technician. This button may
need to be pressed to update
the device.

SPECIFICATIONS AND OPERATING REQUIREMENTS

DynoWare RT Electronics

NETWORK CONNECTIONS

wireless network

internet and router

direct connection

point to point

The Dynojet DynoWare RT dyno electronics connects to your computer directly or
over a Local Area Network. If you have an existing network, connect t he DynoWare RT
main module to a router or a network switch on your network. If you don't have an
existing network, you can create a network for the DynoWare RT by connecting the
main module to a router.

There are some advantages to connecting the DynoWare RT to a network, particularly
a wireless network. With DynoWare RT on a network, you don't have to have one
dedicated computer for the dyno. Any computer on the network can connect and
operate the dyno. A wireless connection allows you to control the dyno from inside the
vehicle without a cable running to the DynoWare RT main module.

Note: Only one computer at a time can connect.

When the DynoWare RT main module is on a network connected to the internet,
automatic updates for both the box and software are possible.

connection method auto updates

Wireless Network
Internet

Wireless Network
Router

Direct Connection
Point to Point

Yes Yes Yes

multi-computer
connection wireless connection

Yes Yes

Figure 1-4: DynoWare RT Network Connections

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

1-13

CHAPTER 2

This chapter will walk you through unpacking and installing the dynamometer. To
ensure safety and accuracy in the procedures, perform the procedures as they are
described.

This chapter is divided into the following categories:

• Unpacking and Inspecting the Dyno, page 2-2

• Dyno Installation, page 2-10

• Battery, page 2-13

• Pickup Card, page 2-14

• Eddy Current Brake, page 2-15

• Secure the Drum and Brake Module to the Floor, page 2-23

• Remove the Dyno Covers, page 2-24

• iX Drum Module Installation, page 2-25

I

NSTALLATION

• Cable Routing, page 2-32

• Side and Top Covers, page 2-40

• Fan Arm Mounts, page 2-44

• Trike Carriage Adapter and Carriage Assembly, page 2-45

• Monitor Support and Tray, page 2-49

• Control Panel and Cable, page 2-50

• Final Adjustments and Tests, page 2-53

• Zip Tube, page 2-55

• Ground Hooks, page 2-56

• Ramp Bracket, page 2-57

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-1

CHAPTER 2

Unpacking and Inspecting the Dyno

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-2

UNPACKING AND INSPECTING THE DYNO

D036

C

tire carriage

support arm

When you receive your dyno, examine the exterior of the shipping container for any
visible damage. If damage is detected at this stage, contact the shipper or Dynojet
before proceeding with unpacking.

Use the following steps to unload your dyno. You will need to provide equipment
capable of lifting a minimum of 1,133.98 kg (2,500 lbs.) to move the crated dyno into
position in your dyno room. Refer to “Forklift Requirements” on page 1-9 for more
information.

1 Move the crated dyno to a clear area near your dyno room.
2 Using a pry bar, or a large flat screwdriver, and a hammer, remove the top and

sides of the crate.

3 Inspect the exterior of the dyno for any indications of damage. Report any damage

immediately.
4 Remove the tire carriage. The tire carriage is fastened to the bottom of the crate.
5 Remove the support arm. The support arm is fastened to the bottom of the crate.

Refer to“Monitor Support and Tray” on page 2-49 for more information.

Figure 2-1: Remove the Tire Carriage and Support Arm from the Crate

INSTALLATION

Unpacking and Inspecting the Dyno

6 Remove the six 1/4-inch screws securing the center panel on the dyno and remove

D037

C

center panel

tire stop and tire lock

in middle

the center panel.

Note: Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to

remove the 1/4-inch screws.
7 Remove the tire stop, tire lock, and hardware from the middle of the dyno.

Figure 2-2: Remove the Center Panel

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-3

CHAPTER 2

Unpacking and Inspecting the Dyno

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-4

8 Remove the eight screws securing the top drum cover to the dyno and set aside.

D 038

C

top drum cover

side drum cover

side drum cover

Remove the drum cover and set aside.
9 Remove the two top screws securing each side drum cover to the dyno and set

aside.

Figure 2-3: Remove the Top Drum Cover

INSTALLATION

Unpacking and Inspecting the Dyno

10 Remove the remaining six side screws securing each side drum cover to the dyno

#

RECORD

D039C

side drum cover

side drum cover

access holes in drum bulkhead

(only two visible from this view)

dyno number stamped

on frame

and set aside. Remove the side drum covers and set aside.

Note: For future reference, note the three access holes in the drum bulkhead.

These access holes will be used to route cables when installing accessories once

the top cover is back on.

Be sure you record the dynamometer number on the inside cover of this
manual.

Figure 2-4: Remove the Side Drum Covers

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-5

CHAPTER 2

Unpacking and Inspecting the Dyno

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-6

Note: Remove the boxes and loose parts from the crate, verify their condition and

contents and set them aside.

part description part description

screw, 8-32 x 3/8", ph, 
phil (15)
P/N 36540643

pendant assembly
P/N 76100007

washer, 3/8", flat (4)
P/N 36923100

anchor, redhead, 3/8" (4)
P/N 37513200

installation tool, redhead
anchor
P/N 37518200

network cable
P/N 42900000

cable harness wrap kit
P/N 43400000

grounding kit
P/N 76100015

see list of parts below

PCV CAN termination plug
P/N 76423025

CAN termination plug 
P/N 76423045

blower assembly
P/N 76722003

optional accessory
see page 3-22

primary inductive 
pickup (2)
P/N 76950201

cable clamp (7)
P/N 43428232

split snap busing (4)
P/N 43991080

secondary inductive 
pickup (2)
P/N 76950203

cable, wheel clamp
P/N 76950307

optional accessory

INSTALLATION

Unpacking and Inspecting the Dyno

part description part description

J. MaxwellJ. Maxwell

battery hold down kit
P/N 49418001

cable, power carriage
P/N 76950308

optional accessory

control panel spindle
P/N 61329000

monitor support and arm
P/N 61329003

monitor tray
P/N 61329101P

eddy current brake
P/N 62900005

tire stop
P/N 63310902

not included if you ordered
the optional wheel clamp

cable, pickup/brake
P/N 76950548

cable, e-stop to CPI
P/N 76950549

cable, load cell
P/N 76950573

optional accessory

cable, CAN powersports
P/N 76950680

cable, CAN dyno user, 15'
P/N 76950798

on dyno air fuel ratio
assembly
P/N 64100008

optional accessory

DynoWare RT main module
P/N 66100016

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

cable, CAN control adapter
P/N 76950807

cable, control panel
P/N 76951501

2-7

CHAPTER 2

Unpacking and Inspecting the Dyno

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-8

part description part description

control panel assembly
P/N 66117001

iX upgrade kit
P/N 77000003

see page 2-25

remote atmos assembly
P/N 66400011

speed pick up
P/N 68300002

ramp bracket assembly
P/N 69100001

carriage assembly
P/N 71323002

or
extended carriage assembly

P/N 78100003

wheel clamp
P/N 71329000

optional accessory
see page 3-27

ground hook kit (6) 
P/N 79190001

see list of parts below

power carriage
P/N 82943001

optional accessory
see page 3-24

banner, dynojet (2)
P/N D706

hand wheel
P/N DM150-016-006

bolt, 3/8-16 x 3/4" hex (4)
P/N DM150-019-008

The following parts are included in the Grounding Kit P/N 76100015:

grounding bracket
P/N 21600084

screw, 1/4-20 x 1/2"
P/N 36560834

cable, vehicle ground
P/N 76950788

INSTALLATION

Unpacking and Inspecting the Dyno

part description part description
The following parts are included in the Ground Hook Kit P/N 79190001:

ground hook/D-ring (1)
P/N 10111

washer, 5/16", flat (2)
P/N DM150-002-007

washer, 3/8", splitlock, steel
(2)
P/N 36932100

anchor, redhead, 3/8" (2)
P/N 37513200

bolt, 3/8-16 x 1", hex (2)
P/N DM150-019-012

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-9

CHAPTER 2

Dyno Installation

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-10

DYNO INSTALLATION

#

RECORD

bolt and washer not

visible from this view

lifting eye

bolt and washer

bolt and washer

lifting eye

bolt and washer

This section will walk you through removing the dyno from the crate and installing the
dyno in your dyno room.

REMOVING THE DYNO FROM THE CRATE

You will need to provide equipment capable of lifting a minimum of 1,133.98 kg
(2,500 lbs.) to lift the dyno off the crate and into position in your dyno room. You will
also need a pair of straps capable of supporting 1,133.98 kg (2,500 lbs.) to attach to the
dyno. Dynojet recommends using a single loop style strap.

Be sure you record the dynamometer number on the inside cover of this
manual.

1 Remove the four lag bolts and washers securing the dyno to the crate base using a

9/16-inch socket, open or box end wrench.
2 The pickup card may be taped to the lifting eye. Remove the pickup card and set it

aside.

Figure 2-5: Remove the Dyno from the Crate Base

INSTALLATION

Dyno Installation

3 Route the single loop strap through the lifting eyes in front of the drum as shown

lifting eye

lifting eye

loop strap

cable routing

bracket

in Figure 2-6.

Note: The dyno should only be lifted using the lifting eyes. Verify no other part of

the dyno is interfering with the strap. Do not place the strap around the cable

routing bracket or any other part of the dyno.

Figure 2-6: Loop Strap Placement

4 Carefully lift the dyno off the crate and move into position in your dyno room.

Note: While the dyno is supported by the forklift and before it is placed in your

dyno room, the power cable must be routed through the front of the dyno.

Figure 2-7: Lift the Dyno off the Crate

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-11

CHAPTER 2

Dyno Installation

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-12

ROUTING THE POWER CABLE

MC076A

strain relief around

power cord

jam nut

inside dyno

opening in

dyno frame

knurled nut

outside dyno

cut away view from

inside dyno

1 Locate the power cable inside the dyno.
2 Slide the strain relief on the power cable through the opening in the dyno frame.
3Tighten the jam nut.
4 Hand tighten the knurled nut.
5 Gently lower the dyno into position. Be sure the location you have chosen for your

dyno has enough room in front of the dyno for the maximum extension of the

carriage. Refer to “Dynamometer Specifications and Requirements” on page 1-5

for more information.

Figure 2-8: Route the Power Cable

INSTALLATION

Battery

BATTERY

CAUTION

MC147

battery

The model 200iX/250iX dyno is designed to carry a group 24 deep-cycle discharge
series battery for operating the starter, optional power carriage, and optional wheel
clamp. The typical dimensions for this series of batteries are 27 cm long by 17 cm wide
by 23 cm tall (10.625-inches by 6.75-inches by 9.125-inches). The mounting is flexible
so a battery that has dimensions close to this will work satisfactorily. The built-in
battery cables are configured for top-post batteries. This battery is not included with
your dyno. You will need to provide this battery.

Note: If you do not wish to use the wheel clamp and the power carriage or operate

the built-in starter then it is not necessary to install the battery.

There is danger of explosion if the battery is incorrectly connected or
replaced. Wear protective clothing, eye, and face protection when
charging or handling batteries. Refer to Warnings for more information.

You will need the following part:

• 49418001 Battery Hold Down
1 Locate the red battery cable on the inside of the dyno.
2 Place the battery in the battery carrier on the inside of the dyno so the red cable

can reach the positive (+) post on the battery and the black battery cable can reach

the negative (-) post.
3 Secure the red battery cable to the positive (+) battery post.
4 Secure the black battery cable to the negative (-) battery post.
5 Secure the battery to the tray with the battery hold down.

Figure 2-9: Install the Battery

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-13

CHAPTER 2

Pickup Card

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-14

PICKUP CARD

CAUTION

pickup card

bracket

pickup card

wheel on dyno

top view of pickup card, optical

pickup, and tab on dyno

wheel on dyno

optical pickup

pickup card

The pickup card is an electronic circuit board that accurately senses each drum
revolution.

1 Locate the pickup card bracket on the right side of the dyno just ahead of the

2 Install the pickup card to the bracket using two No. 8 screws.
3 Align the optical pickup card with the wheel on the dyno drum axle. Be sure the

4 Once aligned, tighten the screws to secure the pickup card bracket in place.

The optical pickup is very delicate. Be careful not to damage the optical
pickup during alignment.

drum.

wheel passes freely through the optical pickup. You may need to loosen the

bracket to help with alignment.

Figure 2-10: Install the Pickup Card

INSTALLATION

Eddy Current Brake

EDDY CURRENT BRAKE

remove boxes

The eddy current brake is an optional accessory. This section will walk you through
removing the eddy current brake from the crate, and attaching the brake to your dyno.
If you did not purchase the eddy current brake, skip this section and continue with the
installation.

You will need to provide equipment capable of lifting the eddy current brake off the
crate and into position in your dyno room. You will also need a pair of straps. Dynojet
recommends using continuous nylon loop style straps.

For more information on routing the eddy current b rake cables, refer to “Cable
Routing” on page 2-32.

To prevent possible injury, verify all power cords are unplugged.

UNPACKING THE EDDY CURRENT BRAKE

1 Remove the top and sides of the crate.

Figure 2-11: Remove the Crate Top

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-15

CHAPTER 2

Eddy Current Brake

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-16

2 Remove any hardware and parts boxes from the crate and verify the box contents.

part description part description

screw, 1/4-20 x 5/8", pan­head, torx (2)
P/N 36561045

woodruff key
P/N 37620622

set screw (2)
P/N 36580404

washer, 3/8", flat (2)
P/N 36923100

see page 2-23

anchor, redhead, 3/8" (2)
P/N 37513200

see page 2-23

installation tool, redhead
anchor
P/N 37518200

see page 2-23

cable, controller
P/N 66952003

see page 2-32

cable, IR temp sensor
P/N 76950569

see page 2-32

cable, CAN control, 15'
P/N 76950791

see page 2-32

bolt, 3/8-16 x 1", hex (2)
P/N DM150-019-012

see page 2-23

INSTALLATION

Eddy Current Brake

3 Remove the four screws securing the top cover and set aside. Remove the cover

#

RECORD

top cover

eddy current brake number

and set aside.

Be sure you record the eddy current brake number on the inside cover of
this manual.

Figure 2-12: Remove the Covers

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-17

CHAPTER 2

Eddy Current Brake

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-18

4 Remove the four bolts securing the brake to the crate.

lifting eye

lifting eye

line up panels

remove bolts, washers, and

nuts from dyno frame

5 Remove the side drum cover, if not already removed, from the dyno. 

Refer to Figure 2-4 on page 2-5.
6 Place the nylon loop strap through the lifting eyes on either side of the brake.
7 Using a forklift, lift the eddy current brake from the crate and place the brake near

the dyno making sure the panels on the brake and dyno are parallel.
8 Remove the eight bolts, washers, and nuts from the dyno frame where the

connector plates will attach.

Figure 2-13: Move the Brake Next to the Dyno

INSTALLATION

Eddy Current Brake

INSTALLING THE EDDY CURRENT BRAKE

key way on dyno shaft

key

connector plate

The eddy current brake comes with the driveline assembly (coupler) already installed
on the brake shaft.

Note: Safety requirements of your local country may require that both the air

brake and eddy current brake are installed. Be sure to follow the safety

requirements specific to your country.
1 Insert the key into the keyway.

2 Use a c-clamp to press the key in, if necessary.

Figure 2-14: Install the Key

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-19

CHAPTER 2

Eddy Current Brake

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-20

3 Keeping the panels parallel, slide the eddy current brake towards the dyno. Slide

EB240

three bolts not visible

from this view

connector plate

the driveline over the key on the dyno shaft. Y ou will ne ed to suppo rt the driv eline

as you slide it onto the dyno shaft.
4 Continue sliding the eddy current brake towards the dyno until the covers on the

brake and dyno are flush.
5 Secure the connector plate to the dyno frame using the four bolts, washers, and

nuts removed earlier. There is a connector plate on either side of the brake. Refer

to Figure 2-15.

Note: Do not tighten the bolts.
6 Verify the covers on the brake and the dyno line up. These covers must be flush

and parallel. If these covers are not flush, place shims between the floor and the

eddy current brake or the dyno until they are flush.
7 Once aligned, tighten all connector plate bolts and nuts.

Figure 2-15: Secure the Connector Plates

INSTALLATION

Eddy Current Brake

8 Secure the side panels on the eddy current brake to the panels on the dyno using a

not visible from

this view

brake shaft

dyno shaft

set screw

1/4-20 bolt. Do this on each side.

Figure 2-16: Secure the Side Panels to the Dyno

9 Replace the existing set screws on the driveline with the thread-lock set screws

provided.
10 Tighten the driveline set screws.

Figure 2-17: Tighten the Set Screws

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-21

CHAPTER 2

Eddy Current Brake

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-22

INSTALLING THE LOAD CELL

distance must be

the same

eyelet

bar

lock nut

PD229

install the load cell

(the brake is not

shown for clarity)

The load cell is an optional accessory. If you did not order a load cell, skip this section.
You will need the following part:

• 76950753 Load Cell Assembly
1Verify the main dyno power is disconnected.
2 Remove the two bolts and nuts securing the existing bar on the eddy current brake

and remove the bar. Set the bolts and nuts aside.

3 Verify the eyelets on the load cell are spaced the same as the bar removed earlier.

Adjust the load cell spacing by loosening the lock nut and turning the eyelet.

4 Secure the load cell to the mounting bracket using the two bolts and nu ts removed

earlier.

Figure 2-18: Verify Load Cell Spacing

Figure 2-19: Install the Load Cell

INSTALLATION

Secure the Dyno and Brake Module to the Floor

SECURE THE DYNO AND BRAKE MODULE TO THE FLOOR

MC122

mark and drill

holes for red

head anchors

mark and drill

holes for red head

anchors

mark and drill

holes for red

head anchors

Dynojet recommends you anchor the eddy current brake, along with the dyno, to the
floor in your dyno room using concrete anchors. You will want to drill the holes and
secure the dyno before adding any accessories or replacing the covers on your dyno.

You will need the following parts:

• 36923100 Washer, 3/8", Hardened, Flat, Steel (6)

• 37513200 Anchor, Redhead, 3/8" (6)

• 37518200 Redhead Anchor Installation Tool

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (6)
1 Using the dyno and brake module as a template, mark and drill each hole needed

to secure the dyno to the floor.
2 Install the Red Head anchors. Refer to Appendix A for installation instructions.
3 Secure the dyno and brake module to the floor using six 3/8-16 x 1-inch hex bolts

and six 3/8-inch flat washers.

Figure 2-20: Secure the Dyno and Brake Module to Floor

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-23

CHAPTER 2

Remove the Dyno Covers

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-24

REMOVE THE DYNO COVERS

top cover

side cover

Before installing the iX upgrade, you will need to remove the top and side cover from
the dyno. Be sure to set the covers and screws aside; these covers will be installed later
on the iX upgrade.

1 Remove the five screws securing the top cover to the dyno and set aside. Remove

the top cover and set aside.
2 Remove the twelve screws securing the side cover to the dyno and set aside.

Remove the side cover and set aside.

Figure 2-21: Removing the Dyno Covers

INSTALLATION

iX Drum Module Installation

IX DRUM MODULE INSTALLATION

When you receive your iX upgrade kit, examine the exterior of the shipping container
for any visible damage. If damage is detected at this stage, contact the shipper or
Dynojet before proceeding with unpacking.

Use the following steps to unload the iX drum module and related items. You will need
to provide equipment capable of lifting a minimum of 363 kg. (800 lb.) to move the
crated drum into position in your dyno room.

Note: If this is an iXW upgrade, refer to Appendix E.

REMOVING THE ITEMS FROM CRATE

1 Move the crate to a clear area near your dyno room.
2 Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the

top and sides of the crate.
3 Remove the following parts from the crate and set aside.

part description part description

middle bulkhead
P/N 21200022

front bulkhead
P/N 21200024

center panel
P/N 21200037

see page 2-42

fan arm mount (2)
P/N 61300009P

see page 2-44

drum module
P/N 62100000

driveline assembly
P/N 62200004

drum safety cover
P/N 21200038

see page 2-42

toe kick bracket
P/N 21600012

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

lower blower arm (2)
P/N 63400002

see page 3-22

trike carriage adapter
assembly
P/N 71300002

see page 2-45

2-25

CHAPTER 2

iX Drum Module Installation

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-26

part description part description

set screw (2)
P/N 36580404

cable, blower power
extension
P/N 76950053

woodruff key (2)
P/N 37620622

monitor support brace
P/N 61300007

4 Remove the crate braces that support the top portion of the crate.
5 Remove the four lag bolts and washers securing the drum to the crate base using a

9/16-inch socket, open or box end wrench.

bolt kit
P/N 79100000

INSTALLATION

iX Drum Module Installation

INSTALLING THE IX DRUM MODULE

#

RECORD

existing screws

iX drum module

driveline

woodruff key

woodruff key

existing screws

You will need the following parts:

• 36561045 Screw, 1/4-20 x 5/8", Ph, Torx (2)

• 36580404 Set Screw (2)

• 37620622 Woodruff Key (2)

• 62100000 iX Drum Module

• 62200004 Driveline Assembly
1 Remove the drum safety cover from the iX drum module.
2 Remove the six screws securing the iX drum cover and set aside. Remove the

cover and set aside.

Be sure you record the iX drum module number on the inside cover of this
manual.

3 Place the nylon loop strap around the shaft on either side of the drum module.
4 Using a forklift, lift the drum module from the crate and place the drum module

near the dyno with the stepped end of the shaft towards the dyno. Make sure the
panels on the drum module and the dyno are parallel.

5 Remove the two existing screws from the dyno frame where the connec t or plates

will attach.
6 Insert the woodruff key into the keyway on the drum module shaft.
7 Insert the woodruff key into the keyway on the dyno shaft.
8 Slide the driveline over the key on the drum module shaft.
9 Keeping the panels parallel, slide the drum module towards the dyno. Slide the

driveline over the key on the dyno shaft. You will need to support the driveline as

you slide it onto the dyno shaft.
10 Continue sliding the drum module towards the dyno until the side panels on the

drum module and the dyno are flush.

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

Figure 2-22: Installing the Driveline and the Drum Module

2-27

CHAPTER 2

iX Drum Module Installation

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-28

11 Secure the connector plate on either side of the drum module to the dyno frame

secure connector plate

not visible from

this view

using the screws removed earlier.
12 Verify the panels on the drum module and the dyno li ne up. The se cov ers must be

flush and parallel. If these covers are not flush, place shims between the floor and

the drum module or the dyno until they are flush.
13 Once aligned, tighten all screws.
14 Secure the side panels on the drum module to the panels on the dyno using one

1/4-20 x 5/8-inch screw.
15 Replace the existing set screws on the driveline assembly with the thread-lock set

screws provided.
16 Tighten the driveline set screws.

Figure 2-23: Securing the Drum Module to the Dyno

INSTALLATION

iX Drum Module Installation

INSTALLING THE BULKHEADS

middle bulkhead

front bulkhead

monitor support

brace

You will need the following parts:

• 21200 022 Middle Bulkhead

• 21200024 Front Bulkhead

• 21600012 Toe Kick Bracket

• 36468100 Nut, 1/4-20, Nylock (5)

• 36561045 Screw, 1/4-20 x 5/8", Ph, Torx (16)

• 61300007 Monitor Support Brace

• 76950053 Cable, Fan Power Extension
1 Place the monitor support brace on the five studs on the front bulkhead.
2 Secure the brace to the studs using five 1/4-20 nylock nuts.
3 Secure the front bulkhead to the dyno frame using four 1/4-20 x 5/8-inch pan-

head torx screws.

4 Secure the middle bulkhead to the dyno frame using five 1/4-20 x 5/8-inch pan-

head torx screws.

Figure 2-24: Securing the Front and Middle Bulkheads

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-29

CHAPTER 2

iX Drum Module Installation

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-30

5 Remove the existing 3/8-inch screw from the drum module and secure the toe

dyno side cover

fan socket

toe kick bracket

kick bracket to the drum module.

6 Attach the blower power extension cable to the existing blower cable,

disconnected earlier, by matching up the colors.

7 Attach the blower power extension cable to the fan socket.

• Connect the brown wire to N

• Connect the blue wire to L

• Connect the green/yellow wire to ground
8 Secure the dyno side cover to the bulkheads using the eleven screws removed

earlier.

Figure 2-25: Securing the Dyno Side Cover

INSTALLATION

iX Drum Module Installation

9 Secure the dyno top cover to the bulkheads using the five screws removed earlier.

dyno top cover

drum side cover

10 Secure the drum side cove r to the dr um module using t he ei ght 1/4-20 x 5/8-inch

button-head screws removed earlier.

Figure 2-26: Securing the Dyno Top Cover and Drum Side Cover

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-31

CHAPTER 2

Cable Routing

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-32

CABLE ROUTING

B

B

Use the following instructions to identify and route the cables. You will need to route
the cables before installing the covers. For the following instructions, the support arm
and control panel will be mounted on the left side of the dyno.

IDENTIFYING THE CABLES

cable brief routing description

A - 42900000 network cable connects the DynoWare RT to your local network

B - 66400011 remote atmos cable assembly connects to the DynoWare RT

C - 76100007 CAN pendant cable assembly connects to the DynoWare RT

D - 76950053 blower power extension cable connects the right blower cable from the CPI to the

E - 76950201 primary RPM pick up cable

- 76950203 secondary pick up cable

F - 76950304 CPI to right blower cable connects the CPI to the AC blower socket on the right

G - 76950307 wheel clamp cable assembly connects the wheel clamp to P5 on the front of the

H - 76950308 power carriage cable assembly connects the power carriage to P8 on the front of the

I - 76950310 DynoWare RT power cable connects the CPI to the DynoWare RT

J - 76950548 speed pick up/brake cable connects the brake solenoid and speed pick up to

AC blower socket on the dyno chassis, see page 2-30

connects to the DynoWare RT

side of the dyno chassis using the blower power
extension cable

CPI panel, see page 2-38
*optional accessory

CPI panel, see page 2-38
*optional accessory

DRUM 1 on the back of the DynoWare RT

INSTALLATION

Cable Routing

cable brief routing description

J. MaxwellJ. Maxwell

!

A

C

C

C

C

K - 76950549 e-stop to CPI cable connects the DynoWare RT to P7 on the front of the

CPI panel

L - 76950569 IR temp sensor cable connects to the temp sensor cable to the eddy current

brake driver

M - 76950573 load cell cable connects the load cell to the eddy current brake

driver
*optional accessory

N - 76950646 AFR power cable connects the CPI to the air fuel module

*optional accessory

O - 76950680 CAN powersports cable connects Dynojet Powersports products to the

DynoWare RT (PCV, OBD2)

P - 76950791 CAN control cable, 15' connects the eddy current brake driver to the

DynoWare RT using the CAN adapter cable or CAN
network cable chain

Q - 76950798 CAN dyno user cable, 15' connects the POD intercept to the DynoWare RT

using the CAN adapter cable

R - 76950798 CAN dyno user cable, 15' connects the air fuel module to the DynoWare RT

S - 76950807 CAN control cable, adapter, 2' connects the DynoWare RT to the CAN control and

using the CAN adapter cable or CAN network cable
chain

*optional accessory

CAN dyno user cables

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CHAPTER 2

Cable Routing

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-34

cable brief routing description

MC154

T - 76951501 control panel cable connects the control panel (POD) to J3 on the POD

intercept board

U - 76423025 PCV CAN termination plug connects to the PCV module when connected to the

DynoWare RT using the CAN Powersports cable

V - 76423045 CAN termination plug connects to the last CAN cable in the CAN network

cable chain

INSTALLING THE DYNOWARE RT MAIN MODULE

You will need the following part:

• 66100016 DynoWare RT Main Module
Slide the DynoWare RT main module into the bracket assembly in the dyno.

Figure 2-27: Install the DynoWare RT Main Module

INSTALLATION

Cable Routing

ROUTING THE CABLES

Use the following instructions along with Figure 2-29 on page 2-37 for routing and
connecting the cables.

You will need the following part:

• 43991080 Split Snap Bushing (2)
1 Remove the two screws securing the cable pass through cover closest to the

monitor support and set it aside.

2 Route the CAN pendant cable (C) through the cable pass through closest to the

monitor support and attach to B on the front of the DynoWare RT module.

3 Route the network cable (A) through the cable pass through closest to the monitor

support and attach to the back of the DynoWare RT module.

4 Route the 15-pin control panel cable (T) from the POD intercept board, through

the cable pass through closest to the monitor support, and attach to the control
panel. Refer to “Control Panel and Cable” on page 2-50.

5 Place a split snap bushing around the pendant cable and secure the cable through

one hole in the cable pass through cover.

6 Place a split snap bushing around the control panel cable and network cable and

secure both cables in the other hole on the cable pass through cover. The bushing
should be around the cable protective wrap.

7 Secure the cable pass through cover to the dyno using the two screws removed

earlier.

8 Attach the speed pickup/brake cable (J) to DRUM 1 on the back of the DynoWare

RT module.
Note: The white two-pin connector on the speed pickup/brake cable is only used

if an air brake is installed.

9 Attach the temp sensor cable (L) to the eddy current brake driver.
10 Attach the load cell cable (M), if present, to the eddy current brake driver.
11 Route the e-stop cable (K) from P7 on the front panel of the CPI to the back of the

DynoWare RT main module.
12 Route the AFR power cable (N) from the DIN rail to the AFR assembly.
13 Insert the O2 sensor(s) into the sensor block on the AFR assembly, plug the sensor

connectors into the AFR, and zip tie the sensor cables away from moving parts.
14 Attach the network cable (A) to your network. Refer to “Network Connections” on

page 1-13.
15 Route the power cable (I) from the DIN rail to the back of the DynoWare RT

module.
16 Attach remote atmos cable (B) to the DynoWare RT module and stick the atmos

module to the side of the dyno.
17 Attach the RPM pickup cable (E) to the front of the DynoWare RT module.

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2-36

18 Attach the CAN adapter cable (S) to C on the back of the DynoWare RT main

module.
19 Attach the CAN dyno user cable (Q) to the CAN adapter cable (S) and route to the

POD intercept board. Attach the CAN dyno user cable (Q) to the POD intercept

board.
20 Attach the CAN control cable (P) to the “T” on the CAN dyno user cable (Q) and

route to the eddy current brake driver. Attach the CAN control cable (P) to the

eddy current brake driver.
21 Attach the CAN dyno user cable (R) to the “T” on the CAN control cable (P) and

route to the AFR assembly. Attach the CAN dyno user cable (R) to the AFR

assembly.

Note: The AFR assembly is an optional accessory.
22 Insert the CAN termination plug (V) in the CAN dyno user cable (R).

Note: If you do not have an eddy current brake and/or AFR assembly, insert the

CAN termination plug (V) at the end of your CAN network cable chain.

Figure 2-28: CAN Network Cable Configuration

INSTALLATION

Cable Routing

23 Remove the PCV CAN termination plug (U) from the front of the DynoWare RT

module and save for use with the PCV module.

23a Attach the PCV or OBD2 module using the CAN powersports cable (O).

23b Insert the PCV CAN termination plug (U) in the PCV module.

Note: If you are not using a PCV, be sure to save the PCV CAN termination 

plug (U) for future use.

Figure 2-29: Routing the Cables

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

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CHAPTER 2

Cable Routing

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-38

ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES

route cables

through

cable pass through

cover

The power carriage and wheel clamp are optional accessories. These cables will only
be used if you ordered the accessories.

For installation instructions refer to “Power Carriage” on page 3-24 and “Wheel
Clamp” on page 3-27 for more information.

You will need the following part:

• 43991080 Split Snap Bushing (2)

1 Remove the two screws securing the cable pass through cover on the front of the

dyno and set aside.
2 Locate the cables bundled inside the dyno.
3 Route the power carriage cable (H) and wheel clamp cable (G) through the

opening in the front of the dyno.

Figure 2-30: Remove the Cable Pass Through Cover

INSTALLATION

Cable Routing

4 Place a split snap bushing around the wheel clamp cable and secure into place in

2-pin power carriage cable, H

3-pin wheel clamp cable, G

one hole on the cable pass through cover.
5 Place a split snap bushing around the power carriage cable and secure into place

in the other hole on the cable pass through cover.
6 Secure the cable pass through cover to the dyno with the two screws removed

earlier.

Figure 2-31: Routing Wheel Clamp and Power Carriage Cables

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CHAPTER 2

Side and Top Covers

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-40

SIDE AND TOP COVERS

Before replacing the center panel, be sure to route all your cables and air hoses and
install any additional accessories you purchases.

Note: If this is an iXW upgrade, refer to Appendix E.
1 Secure the eddy c urrent brake si de cov er to t he ed dy current brake using the eight

1/4-20 x 5/8-inch screws removed earlier.

Figure 2-32: Securing the Eddy Current Brake Side Cover

INSTALLATION

Side and Top Covers

2 Secure the eddy current brake top cover to the eddy current brake six

drum top cover

eddy current brake top cover

dyno center cover

1/4-20 x 5/8-inch screws removed earlier.
3 Secure the drum top cover to the drum using the eight 1/4-20 x 5/8-inch screws

removed earlier.
4 Secure the center cover to the dyno using the six 1/4-20 x 5/8-inch screws

removed earlier.

Figure 2-33: Securing the Eddy Current Brake, Drum, and Dyno Covers

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CHAPTER 2

Side and Top Covers

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-42

INSTALLING THE IX COVERS

center cover

drum top cover

You will need the following parts:

• 21200037 Center Cover, iX

• 21200038 Drum Safety Cover

• 36561045 Screw, 1/4-20 x 5/8", Ph, Torx (6)

1 Secure the drum top cover to the drum module using the six 1/4-20 x 5/8-inch

screws removed earlier.
2 Secure the center cover to the bulkheads using six 1/4-20 x 5/8-inch screws.

Figure 2-34: Securing Drum Top Cover and Center Cover

INSTALLATION

Side and Top Covers

3 Place the drum safety cover over the drum. This cover has two pins to keep it in

drum safety

cover

place.

Risk of injury. Never run a motorcycle on the dyno without this cover in
place.

Figure 2-35: Installing the Drum Safety Cover

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CHAPTER 2

Fan Arm Mounts

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-44

FAN ARM MOUNTS

fan arm mount under

monitor support

fan arm mount on

right side of dyno

Use the following instructions to install the fan arm mounts. For more information on
installing the high pressure blowers, refer to “High Pressure Blowers” on page 3-22.

You will need the following parts:

• 36582034 Bolt, 3/8-16 x 1.25", Button-head, Flange (8)

• 61300009 Fan Arm Mount (2)

1 Install the fan arm mount on the right side of the dyno using four 3/8-16 x 1.25-

inch button-head flange screws.
2 Place the fan arm mount on the left side of the dyno, but do not secure.

Note: Do not secure the fan arm mount used with the monitor support until the

monitor support is in place. Refer to step 1 on page 2-49 for more information.

Figure 2-36: Installing the Fan Arm Mounts

INSTALLATION

Trike Carriage Adapter and Carriage Assembly

TRIKE CARRIAGE ADAPTER AND CARRIAGE ASSEMBLY

5/16 x 1-inch bolts

3/8 x 1-inch bolts

trike carriage

adapter assembly

Use the following instructions to install the trike carriage adapter assembly, carriage,
tire stop, and tire lock.

You will need the following parts:

• 15331100 Chain Lube

• 36500008 Screw, 5/16-UNC x 1", Button-head (6)

• 36500009 Screw, 3/8-16UNC x 1", Button-head (2)

• 63310902 Tire Stop Assembly

• 71300002 Trike Carriage Adapter Assembly

• 71323002 Carriage Assembly

INSTALLING THE TRIKE CARRIAGE ADAPTER ASSEMBLY

1 Secure the trike carriage adapter assembly to the dyno using six 5/16 x 1-inch

button-head screws where the carriage assembly was installed and two 

3/8 x 1-inch button-head screws as shown in Figure 2-37.
2 Lube the tracks with the included lube or use grease.

Figure 2-37: Installing the Trike Carriage Adapter Assembly

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CHAPTER 2

Trike Carriage Adapter and Carriage Assembly

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-46

INSTALLING THE CARRIAGE ASSEMBLY

screw

bearing
bracket

carriage

screw

1 Remove the four 1/4 x 20-inch button-head screws securing the bearing bracket.
2 Remove the bearing bracket and the carriage screw.

Figure 2-38: Remove the Bearing Bracket and Carriage Screw

INSTALLATION

Trike Carriage Adapter and Carriage Assembly

3 Starting from the back of the dyno, slide the carriage under the carriage clamps.

carriage

trike carriage

adapter assembly

nut block

carriage screw

hand crank

4 Slide the carriage screw and the bearing bracket toward the nut block until the

carriage screw is touching the nut block.
5 Slide the hand crank onto the end of the carriage screw.
6 Secure the hand crank to the screw shaft by tightening the set screw using a 

5/32-inch allen wrench.
7 Using the hand crank, or the control panel to run the power carriage, run the

carriage screw through the nut block and into the screw support bracket on the

carriage assembly.
8 Secure the bearing bracket to the carriage assembly using the four 

1/4-20 x 1/2-inch button-head screws removed earlier.

Note: If you ordered the power carriage accessory, refer to “Power Carriage” on

page 3-24 for installation instructions.

Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

Figure 2-39: Installing the Carriage Assembly

2-47

CHAPTER 2

Trike Carriage Adapter and Carriage Assembly

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-48

9 Secure the tire stop to the carriage using four 3/8-16 x 1/2-inch button-head

tire lock

tire stop

flange bolts.
10 Secure the tire lock to the carriage using four 3/8-16 x 1/2-inch button-head

flange bolts.

Note: If you purchased the wheel clamp accessory, refer to “Wheel Clamp” on

page 3-27 for installation instructions.

Figure 2-40: Install the Tire Lock and Tire Stop

INSTALLATION

Monitor Support and Tray

MONITOR SUPPORT AND TRAY

monitor
support

fan arm mount under

monitor support

washer

tray

arms

washers

You will need the following parts:

• 26215520 Washer, 1/8", Poly, for Monitor Support (3)

• 35521420 Cap Plug, for Monitor Support (4)

• 36582034 Bolt, 3/8-16 x 1.25", Button-head, Flange (4)

• 61329100P Monitor Arm (2)

• 61329101P Monitor Tray

• 61329500P Monitor Support

1 Secure the monitor support to the dyno using four 3/8-16 x 1.25-inch button-head

flange bolts.

Note: Make sure the fan arm mount is sandwiched in between the dyno panel and

the monitor support base.
2 Place a 1/8-inch thick poly washer around the pin on the lower monitor arm.

3 Insert the pin on the lower monitor arm into the monitor support.
4 Place a 1/8-inch thick poly washer around the pin on the upper monitor arm.
5 Insert the pin on the upper monitor arm into the lower blower arm.
6 Place a 1/8-inch thick poly washer around the pin on the monitor tray.
7 Insert the pin on the monitor tray into the upper blower arm.

Figure 2-41: Installing the Monitor Support and Tray

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CHAPTER 2

Control Panel and Cable

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-50

CONTROL PANEL AND CABLE

CP029

CP030

control panel cable with

cable harness wrap

access hole

cable tie

button board

Use the following instructions to route the control panel cable and install the control
panel to the support arm or monitor tray.

You will need the following parts:

• 36540643 Screw, 8-32 x 3/8", Ph, Phil (13)

• 43428232 Cable Clamp (7)

• 61329000 Control Pod Spindle

• 66117001 Control Panel Assembly

1 Remove the control panel rear cover.

1a Remove the two nuts from the top of the cover and set aside.

1b Remove the screw on the top of the cover and set aside.

1c Remove the screw on the side of the cover and set aside.

1d Remove the four screws on the back of the cover and set aside.

1e Remove the control panel rear cover and set aside.

Figure 2-42: Remove the Control Panel Rear Cover

2 Route the control panel cable through the access hole on the side of the control

panel box and through the cable tie.
3 Attach the control panel cable to the Button board.

Figure 2-43: Attach the Control Panel Cable to the Button Board

INSTALLATION

Control Panel and Cable

4 Tighten the cable tie.

CP031

5 If you purchased the optional air brake, install the Emergency Stop Sticker at this

time. Refer to page 3-5 for directions.
6 Secure the rear cover to the control panel.

6a Replace the four screws on the back of the cover removed earlier.

6b Replace the screw on the top of the cover removed earlier.

6c Replace the screw on the side of the cover removed earlier.

6d Replace the two nuts removed from the top of the cover removed earlier.

Figure 2-44: Replace the Control Panel Rear Cover

7 Secure the control panel to either side of the monitor tray using two 8-32-inch

screws.

Note: If you did not order a monitor tray, you will need to install the control pod

spindle on the bottom of your control panel using four 8-32 screws as shown in

the detail in Figure 2-45. Once installed, place the pin on the control panel into the

support arm where the monitor tray is.
8 Place the pendant in the slot provided on the control panel.

Note: If you plan on routing your cables through a zip tube refer to “Zip Tube” on

page 2-55 and skip the following steps.
9 Route the cable bundle along the support arms with service loops to allow

movement as shown below.
10 Using the provided cable clamps and 8-32-inch screws, attach the cable bundle to

the arms and the support arm. Adjust the service loops to allow for easy

movement of the monitor arms without pulling on the cables.

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CHAPTER 2

Control Panel and Cable

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-52

Note: You may want to route the RS232 connector to your computer part way up

control panel

CP023

install control panel

spindle if you did not

purchase the monitor

tray

the support arm along with the control panel and pendant cables depending on

where you your computer is located.

Figure 2-45: Install the Control Panel

INSTALLATION

Final Adjustments and Tests

FINAL ADJUSTMENTS AND TESTS

power plug

main circuit

breaker

After you have installed all of your additional accessories and routed all necessary
cables, perform the following procedures to ensure the safe and effective operation of
your dyno.

Note: Before you plug in your dyno, you or your electrician must refer to

Appendix B for detailed power information.

TURNING ON THE DYNO POWER

1 Plug the power plug into the power outlet.
2 Turn on the main circuit breaker inside the CPI door.

Note: Use the main circuit breaker to turn power on and off to the dyno.

Figure 2-46: Turn on the Dyno Power

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CHAPTER 2

Final Adjustments and Tests

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-54

HIGH PRESSURE BLOWER TEST

Test the blowers by pressing the appropriate buttons on the control panel.

POWER CARRIAGE FINAL ADJUSTMENTS AND TESTS

The power carriage is an optional accessory. To install the power carriage, refer to
“Power Carriage” on page 3-20. Refer to “Using the Power Carriage” on page 4-5 for
more information on using the power carriage. To route the power carriage cables,
refer to “Routing the Power Carriage and Wheel Clamp Cables” on page 2-38.

Using the Control Panel, press the carriage forward and backward buttons and verify
that the motor does turn.

TRIKE CARRIAGE ADAPTER ASSEMBLY TEST

1 Using the supplied chain lube or grease, lube the front and rear adapter slides

(unpainted part).
2 Pull the pin up to slide the carriage until the pin locks into the next locat ion. Verify

the carriage slides left and right on the trike adapter plate.

WHEEL CLAMP FINAL ADJUSTMENTS AND TESTS

The wheel clamp is an optional accessory. To install the wheel clamp, refer to “Wheel
Clamp” on page 3-24. To route the wheel clamp cables, refer to “Routing the Power
Carriage and Wheel Clamp Cables” on page 2-38.

1 Place a stack of catalogs into the wheel clamp.
2 Using the Control Panel, press the close button and observe that the wheel clamp

does close. Hold the button until the motor turns off and the status light is on

steady.
3 Press and hold the right hand wheel clamp button then press the left hand button

to open the clamp.

Refer to “Using the Wheel Clamp” on page 4-6 for more information on using the

Control Panel.

INSTALLATION

Zip Tube

ZIP TUBE

cable(s)

cable holder

guide body

end of cables

guide body

zip tube

end of cables

cable wrap tool

The zip tube encases the multiple cables running to the control panel.
You will need the following parts:

• 16510001 Cable Wrap Tool

• 43431060 Zip Tube
1 Rotate the cable holder to the open position.
2 Insert the cable(s) into the cable holder.

•Pendant Cable

• Control Panel Cable

•RPM cable(s)

• Additional cables, if desired

Figure 2-47: Insert the Cable(s) Into the Cable Holder

3 Rotate the cable holder closed.
4 Insert the guide body into the zip tube.

Note: Make sure you start the cable wrap tool close to the end of the cables. This
will make it easier to pull the tool along the length of the cables.

5 Pull the cable wrap tool through the zip tube along the length of the cables.

Figure 2-48: Secure the Cable(s) Into the Zip Tube

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CHAPTER 2

Ground Hooks

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-56

GROUND HOOKS

Use the following instructions to place and install the ground hooks. You may wish to
change the location of the ground hooks when using a ramp with the dyno; place the
ground hooks in a location that works best for your dyno application.

You will need the following parts:

• 10111 Ground Hook/D-Ring (2)

• 36932100 Washer, 3/8", Splitlock, Steel (4)

• 37513200 Anchor, Redhead, 3/8" (4)

• DM150-002-007 Washer, 5/16", Flat (4)

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (4)
1 Mark the ground hook placement as shown in Figure 2-49. Two additional ground

hooks are included for installation in front of the dyno; placement will vary
depending on dyno application.

2 Using the ground hook as a template, mark and drill each hole needed to secure

the ground hooks to the floor.
3 Install the Red Head anchors. Refer to Appendix A for installation instructions.
4 Secure each ground hook to the floor using two 3/8-16 x 1-inch hex bolts, two

5/16-inch flat washers, and two 3/8-inch lock washers.

Figure 2-49: Ground Hook Placement

INSTALLATION

Ramp Bracket

RAMP BRACKET

ramp lip

ramp bracket

24 inches

The ramp bracket allows you to attach your own ramp to the dyno. You will need to
modify your ramp to secure it to the ramp bracket.

If you purchased the folding ramp option, refer to Appendix D.
You will need the following part:

• 21629203 Ramp Bracket

1 With the ramp upside down, center the ramp bracket under the lip at the top of

the ramp.
2 Using the larger holes on the bracket, mark and drill two 3/8-inch holes in the

ramp.

Figure 2-50: Mark and Drill Ramp Bracket Holes

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CHAPTER 2

Ramp Bracket

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

2-58

3 Insert the 3/8-inch bolts from the top of the ramp and secure using 3/8-inch

washers and nuts.

Figure 2-51: Secure the Bolts to the Ramp

4 Remove the four 1/4-inch bolts from the rear of the drum cover.
5 Secure the ramp bracket to the rear drum cover using the bolts you just removed.

Figure 2-52: Secure the Bracket to the Drum Cover

INSTALLATION

Ramp Bracket

6 Place the ramp on the ramp bracket slipping the bolts on the ramp through the

large holes on the ramp bracket.

Figure 2-53: Place the Ramp on the Dyno

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CHAPTER 3

This chapter discusses the various optional accessories that are available for the
Dynojet Motorcycle Dynamometer (dyno) to meet your individual needs. All of these
options can be added at the factory at the time of original dyno purchase, or purchased
separately and added at any time thereafter. For more information about these
accessories, please contact Dynojet’s Product Specialists at 1-800-992-3525 for
pricing and availability. Installation instructions for some of these options can be
found in this chapter.

This chapter is divided into the following categories:

• Main Dyno Power, page 3-2

• Air Brake, page 3-3

• Air Fuel Ratio Module, page 3-16

• Extended Carriage, page 3-17

• High Pressure Blowers, page 3-22

• Power Carriage, page 3-24

A

CCESSORIES

• Wheel Clamp, page 3-27

• Final Adjustments and Tests, page 3-30

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

3-1

CHAPTER 3

Main Dyno Power

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

3-2

MAIN DYNO POWER

power plug

main circuit

breaker

Many instructions in this guide will require you to connect or disconnect the power to
the dyno as part of the installation process. Use the following steps to connect and
disconnect power to the dyno.

Note: Before you plug in your dyno, you or your electrician must refer to

Appendix B for detailed power instructions.

Always turn the power off when connecting and disconnecting cables.

1 Use the main circuit breaker to turn power on and off to the dyno.

The main circuit breaker is located inside the CPI door. When the handle is in the

down position all power into the dyno is turned off.
2 Disconnect the power plug to ensure all power has been removed from the dyno

before performing certain installation procedures.

Figure 3-1: Main Dyno Power

ACCESSORIES

Air Brake

AIR BRAKE

A 127B

connect shop air supply

The air brake (P/N 63920008) comes installed and ready to use. You will need to
provide an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply
(60 psi, 415 kilopascal, max constant line pressure) to the dynamometer. Once air
pressure is connected and the air brake cable is routed, the air brake is ready to use.

Figure 3-2: Connect Your Shop Air Supply

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CHAPTER 3

Air Brake

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

3-4

ROUTING THE AIR BRAKE CABLES AND AIR HOSE

1 Route the white two-pin connector from the speed pickup/brake cable to the

solenoid leads on the brake assembly.
2 Attach the two-pin connector to the brake solenoid leads.
3 Route the E-stop cable from the rear of the DynoWare RT module to P7 on the CPI

front panel.
4 Attach the two-pin connector to the DynoWare RT module.
5 Attach the flat four-pin connector to P7 on the CPI board.
6 Route the air hose from the air brake through the access hole in the drum module

upright, under the carriage frame brace, and connect to the bulkhead fitting at the

front of the dyno.

You will need to provide an air hose nipple (1/4-inch NPT) to connect your clean,

dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the

dynamometer.

Figure 3-3: Route the Air Brake Cables and Air Hose

ACCESSORIES

Air Brake

INSTALLING THE EMERGENCY STOP STICKER

CP029

A properly installed air brake option adds an emergency stop function to the dyno
shutdown button. With the air brake installed, activating the dyno shutdown button
applies the brake and stops the drum. Installing the emergency stop sticker indicates
the added functionality applied to the dyno shutdown button.

1 Remove the control panel rear cover.

1a Remove the two nuts from the top of the cover and set aside.

1b Remove the screw on the top of the cover and set aside.

1c Remove the screw on the side of the cover and set aside.

1d Remove the four screws on the back of the cover and set aside.

1e Remove the control panel rear cover and set aside.

Figure 3-4: Remove the Control Panel Rear Cover

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CHAPTER 3

Air Brake

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

3-6

2 Remove the Button board.

CP032

button board

screw

CP033

switch body nut

switch body

2a Remove the four screws securing the Button board to the control panel and

set aside.

2b Remove the Button board and set aside.

Figure 3-5: Removing the Button Board

3 Unscrew the black switch body nut and remove the switch body. Set the nut and

switch body aside.

Figure 3-6: Removing the Switch Body

ACCESSORIES

Air Brake

4 Place the emergency stop sticker over the dyno shutdown sticker.

CP015

97415160

S

H

U

T

D

O

W

N

D

Y

N

O

place emergency
stop sticker here

Figure 3-7: Placing the Emergency Stop Sticker

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Air Brake

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3-8

5 Secure the switch body to the control panel using the switch body nut removed

CP033

switch body

switch body nut

control panel

CP032

button board

screw

earlier.

Figure 3-8: Replacing the Emergency Stop Button

6 Secure the Button board to the control panel using the four screws removed

earlier.

Figure 3-9: Securing the Button Board

ACCESSORIES

Air Brake

7 Secure the rear cover to the control panel.

CP029

7a Replace the four screws on the back of the cover removed earlier.

7b Replace the screw on the top of the cover removed earlier.

7c Replace the screw on the side of the cover removed earlier.

7d Replace the two nuts on the top of the cover removed earlier.

Figure 3-10: Replace the Control Panel Rear Cover

AIR BRAKE FINAL ADJUSTMENTS AND TESTS

1 Verify the dyno is set up properly, the dyno electronics is powered up and

operational, and the air supply is connected properly.
2 Use the red brake button on the pendant or the emergency stop button on the

control panel to activate and deactivate the brake. Listen for air leaks and double

check all connections.
3 Verify the brake pads release far enough so they do not touch the rotor. There

should be equal pad clearance on both sides of the rotor. If the pads touch the

rotor during a run, the information provided by the dyno will be inaccurate. 



Refer to “Adjusting the Brake Pad Clearance” on page 3-15 for instructions on

adjusting the brake pad clearance.

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Air Brake

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CHANGING THE BRAKE PADS

remove hairpin cotter

adjust castle nut

outboard brake pad

To prevent possible injury, open the CPI door and set the main breaker to
the off position and unplug the dyno. Refer to “Main Dyno Power” on page
3-2 for breaker location.

1 Remove the top and right side covers from the dyno.
2 For safety, apply the brake and disconnect the air supply at the front of the dyno.

Refer to Figure 3-2 on page 3-3.
3 Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor.

Figure 3-11: Loosen the Castle Nut

ACCESSORIES

Air Brake

4 Using a 9/16-inch ratchet and wrench, remove the bolt, washer, and nut securing

bolt

bolt

nut, washer, and spring

nut, washer,

and spring

the spring to the brake assembly. The spring is located on the drum side of the

brake assembly.

Note: For clarity, the drum is not shown.

Figure 3-12: Remove the Brake Spring

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Air Brake

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5 Remove the two bolts and two washers securing the brake caliper stop to the brake

brake caliper stop

brake bracket

bottom clevis pin

hairpin cotter

bracket and remove the brake caliper stop.

Note: For clarity, the drum and parts of the dyno frame are not shown.

Figure 3-13: Remove the Brake Caliper Stop

6 Remove the hairpin cotter from the bottom clevis pin located on the front of the

air brake assembly.

Figure 3-14: Remove the Bottom Hairpin Cotter

ACCESSORIES

Air Brake

7 Push the bottom clevis pin towards the back of the assembly (drum side). You do

bottom clevis pin

top hairpin cotter

top clevis pin

top clevis pin

not need to remove the pin completely.
8 Remove the hairpin cotter from the top clevis pin located on the drum side of the

air brake assembly.

Figure 3-15: Remove the Bottom Pin and the Top Hairpin Cotter

9 Remove the top clevis pin.

Figure 3-16: Remove the Top Clevis Pin

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10 Lift the air brake assembly up and away from the dyno.

Figure 3-17: Remove the Brake Assembly

11 Remove the brake pad retaining springs and slide the pads out.

Note: You will need to use pliers to remove the spring securing the outside pad

(closest to the castle nut).
12 Install the new brake pads and secure the pads with new springs.

13 Place the air brake assembly back on the brake bracket. Refer to Figure 3-17.
14 Replace the top and bottom clevis pins and secure with the hairpin cotters

removed earlier. Refer to Figure 3-14, Figure 3-15, and Figure 3-16.
15 Using two bolts and two washers, secure the brake caliper stop to the brake

bracket. Refer to Figure 3-13.
16 Secure the spring using the bolt, washer, and nut you removed earlier. Refer to

Figure 3-12.
17 Tighten the castle nut and replace the hair pin cotter. Refer to Figure 3-11.
18 Adjust the brake pad clearance. Refer to“Adjusting the Brake Pad Clearance” on

page 3-15 for complete instructions.
19 Replace the top and right side covers.
20 Connect your shop air.