Dynojet 250i User Manual

Model 200i and 250i Motorcycle Dynamometer Installation Guide.

This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, and the software described in it, 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: 98220104 Version 5 (5/06)

RECORD

Dynamometer Number: ____________________________________________________

Eddy Current Brake (Retarder) Number:_________________________________________________________

ABLE OF

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

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

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

Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Ground Hook Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Model 200i Motorcycle Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Model 250i Motorcycle Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

Model 200i and 250i Motorcycle Dynamometer Installation Guide

TABLE OF CONTENTS

Chapter 2 Installation

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

Unpacking and Inspecting Your Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Routing the Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Positioning and Securing the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

Securing the Drum and Brake Module to the Floor . . . . . . . . . . . . . . . . . 2-19

Installing the Theta Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Support Arm and Monitor Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Installing the Support Arm and Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Routing Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Routing the Pendant, RS232 Computer Cable, and Control Panel Cable .2-25

Routing the Eddy Current Brake Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Wiring the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Routing the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . . . . 2-32

Tire Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Drum Side and Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Ramp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Ground Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

Zip Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Chapter 3 Accessories

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

Remove and Replace Dyno and Drum Covers . . . . . . . . . . . . . . . . . . . . . .3-3

Removing the Drum Top and Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removing the Center Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Routing the Air Brake Cable and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Air Pump and Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Installing the Filter and Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Cleaning the Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Pump Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Removing the Standard Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Installing the Extended Carriage Support Bracket . . . . . . . . . . . . . . . . . . .3-31

Installing the Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

High Pressure Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Installing the Blower Arm Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

Installing the High Pressure Blower Assemblies . . . . . . . . . . . . . . . . . . . . .3-40

Connecting Power to the Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Removing the Hand Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

Installing the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . 3-49

Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . .3-49

TAB LE OF CONT ENTS

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

iii

TABLE OF CONTENTS

Chapter 4 Control Panel Interface Operation

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

Basic Control Panel 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 Dyno Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

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

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

Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Replacing the Theta Controller Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

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

Chapter 5 Basic Dyno Operation

Loading the Bike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . .5-7

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

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

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

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

Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

Appendix A Red Head Anchor Installation

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

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

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

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Appendix B Power Requirements

Locations Using 60Hz Power (North America & Japan) . . . . . . . . . . . . . . B-2

Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Connecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Locations Using 50 Hz Power

(Locations Other than North America and Japan) . . . . . . . . . . . . . . . . . . . B-7

Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

Connecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11

Appendix C Theta Controller

Power Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Accessing the Dip Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

TAB LE OF CONT ENTS

Appendix D EEC Kit

EEC Finger Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

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

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

Adjusting the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6

Installing the Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6

Appendix E Standard and Extended Tire Carriage Installation— Discontinued

Standard Tire Carriage—Discontinued . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Installing the Standard Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Extended Tire Carriage—Discontinued . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6

Installing the Extended Tire Carriage Support Bracket . . . . . . . . . . . . . . . . E-6

Installing the Extended Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9

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

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

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 and instructions that must be followed for proper operation. Power requirements and installation can be found in Appendix B. Failure to follow these instructions could result in personal injury or damage to the dynamometer. 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.

Model 200i and 250i Motorcycle Dynamometer Installation Guide

vii

WARN INGS

Electrostatic Discharge Precautions

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 dyn amo me ter s t o be ver y t ole ran t o f st ati c sh oc ks 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 objects 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 difference of potential before the electronics 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 positive 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.

viii

Model 200i and 250i Motorcycle Dynamometer Installation Guide

WARNINGS

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.

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. Verify brake operation before beginning any dynamometer testing. Verify the vehicle is properly secured 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 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

C HAPTER

PECIFICATIONS AND

Thank you for purchasing Dynojet’s Model 200i/250i 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 WinPEP 7 software and a Dynojet dynamometer will give you the professional results you are looking for.

This document provides instructions for installing the Dynojet’s Model 200i/250i Motorcycle Dynamometer (dyno). 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: 98220104

PERATING

EQUIREMENTS

Versio n 5

Last Updated: 4-13-06

This chapter is divided into the following categories:

•Introduction, page 1-2

• Dynamometer Specifications and Requirements, page 1-5

• Model 200i Dynamometer, page 1-9

• Model 250i Dynamometer, page 1-10

Model 200i and 250i Motorcycle Dynamometer Installation Guide

1-1

CHAPTER 1

Introduction

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 all locations.

THETA CONTROLLER

This appendix describes how to make power adjustments to the theta controller.

EEC KIT

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

STANDARD AND EXTENDED TIRE CARRIAGE INSTALLATION—DISCONTINUED

This appendix describes the procedures for installing the standard and extended tire carriage without the easy removal bracket.

1-2

Model 200i and 250i Motorcycle Dynamometer Installation Guide

SPECIFICATIONS AND OPERATING REQUIREMENTS

CONVENTIONS USED IN THIS MANUAL

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

RECORD

dynamometer and/or eddy current brake (retarder) number on the inside cover of this manual.

Introduction

Bold

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, 3D visualizations, and press releases about our latest product lines.

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

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.”

• 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.

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

1-3

CHAPTER 1

Introduction

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. Plans for exhaust extraction (P/N 73429201) are available from Dynojet.

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 98129103).

Figure 1-1: Custom Dyno Room

1-4

Model 200i and 250i Motorcycle Dynamometer Installation Guide

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 200i/250i 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 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. For more information on installing the battery, refer to “Installing the Battery” on page 2-10.

CHASSIS SPECIFICATIONS

description specifications

Length

with standard carriage allow 271.78 cm (107.00 inches)

with extended carriage allow 322.58 cm (127.00 inches)

Height

to top of dyno cover 45.97 cm (18.10 inches)

Width

model 200i 106.68 cm (42.00 inches)

model 250i 179.60 cm (70.71 inches)

Weight

model 200i dyno/crated dyno 725 kg (1600 pounds)/771 kg (1700 pounds)

model 250i dyno/crated dyno 1,077.28 kg (2,375 pounds)/1,133.98 kg (2,500 pounds)

Drum

diameter 45.72 cm (18.00 inches)

width 50.80 cm (20.00 inches)

Frame structural steel channel and angle Maximum Speed 322 KPH (200 MPH)

Maximum Motorcycle Length (front of front wheel to center of rear wheel)

standard carriage 213 cm (84.00 inches)

extended carriage 256.54 cm (101.00 inches)

Remote Switches remote software control

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

1-5

CHAPTER 1

Dynamometer Specifications and Requirements

model 200i

carriage: allow 68.33 cm (26.9 in.)

extended carriage: allow

119.38 cm (47.0 in.)

45.97 cm (18.10 in.)

152.40 cm

(60.00 in.)

model 250i

179.60 cm (70.71 in.)

106.68 cm (42.00 in.)

127.74 cm (50.29 in.)

72.92 cm

(28.71 in.)

202.77 cm (79.83 in.)

carriage: allow 68.33 cm (26.9 in.)

extended carriage: allow

119.38 cm (47.0 in.)

45.97 cm (18.10 in.)

202.77 cm (79.83 in.)

1-6

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Figure 1-2: Model 200i and 250i Dimensions

COMPRESSED AIR REQUIREMENTS

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)

SPECIFICATIONS AND OPERATING REQUIREMENTS

Dynamometer Specifications and Requirements

COMPUTER SPECIFICATIONS

You will need to provide a computer system to run the WinPEP software. WinPEP 7 includes complete documentation in online Help. From the WinPEP 7 menu bar, choose Help name and password). Refer to the section on Computer Specifications in the WinPEP documentation, P/N 98118103, for the specific computer system requirements.

WinPEP 7 Help or visit www.winpep.com (accessible with a valid user

ELECTRICAL REQUIREMENTS

The Model 200i/250i dynamometers require a 240V - 30a single-phase electrical circuit for reliable and precise operation. No other loads should be plugged into this circuit and this circuit 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.

description specifications

Power Requirements 240v 30 amp single phase circuit Frequency 50 or 60 Hz

Voltage

normal 240 VAC

min./max 215 VAC/245 VAC except Japan 195 VAC/245 VAC

Current 30 amps

Power Consumption 7200 watts Power Cord P/N 76950401

length 3.048 m (10 ft.)

end twist-lock plug or three-pin IEC plug

wall receptacle (included with dyno) twist-lock four wire grounded 30A NEMA L14-30 or

three-pin IEC grounded 30A

Full Load Amperage (FLA) 30A

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

1-7

CHAPTER 1

Dynamometer Specifications and Requirements

ENVIRONMENTAL REQUIREMENTS

description specifications

Te mp e r at u r e

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 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 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 pit 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, install the Red Head anchors using the hardware included with the ground hook kit. Install the Red Head anchors according to the instructions in Appendix A.

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 downloading 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.

1-8

Model 200i and 250i Motorcycle Dynamometer Installation Guide

SPECIFICATIONS AND OPERATING REQUIREMENTS

Model 200i Motorcycle Dynamometer

MODEL 200i MOTORCYCLE DYNAMOMETER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tire Carriage

Tie-down Loop

used to secure the

motorcycle to dyno

Drum

precision balanced

and knurled

Breaker

Breakout Board

Power Cord

Dyno Electronics Enclosure

houses the dyno electronics and

Air Connector

Figure 1-3: Model 200i Basic Dyno

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

power supply

Control Panel Interface

houses the Breakout board, main

power breaker, and battery disconnect

1-9

CHAPTER 1

Model 250i Motorcycle Dynamometer

MODEL 250i MOTORCYCLE DYNAMOMETER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Carriage

not shown

Wheel Clamp

not shown

Control Panel

not shown

Eddy Current

Brake Module

Monitor Tray

supports the monitor, keyboard, and mouse

High Pressure Blower

cools the bike’s engine

Theta Controller

controls the eddy

current brake

1-10

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Drum

precision balanced

and knurled

Figure 1-4: Model 250i With Optional Accessories

Tire Carriage

Tie-do wn Lo op

used to secure the

motorcycle to dyno

Air Brake

Air Pump Assembly

C HAPTER

NSTALLATION

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:

• Dyno Installation, page 2-2

• Battery, page 2-10

• Pickup Card, page 2-11

• Eddy Current Brake, page 2-12

• Support Arm and Monitor Tray, page 2-21

• Dyno Electronics, “Dyno Electronics” on page 2-23

• Routing Cables, page 2-25

• Tire Carriage Installation, page 2-34

• Drum Side and Top Covers, page 2-38

• Ramp Bracket, page 2-40

• Ground Hooks, page 2-43

• Zip Tube, page 2-44

Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-1

CHAPTER 2

Dyno Installation

DYNO INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The following directions describe how to unpack, and install your dyno. Follow the directions in the order that they are presented.

UNPACKING AND INSPECTING YOUR DYNO

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 “Dynamometer Specifications and Requirements” on page 1-5 for more information.

1 Remove the crate braces and sides.

Note: At this point, you will want to inspect the exterior of the dyno for any indications of damage. Report any damage immediately.

2 Remove the tire carriage. The tire carriage is fastened to the bottom of the crate. 3 Remove the support arm. The support arm is fastened to the bottom of the crate.

For more information on the support arm and monitor tray refer to page 2-21.

support arm

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

2-2

Model 200i and 250i Motorcycle Dynamometer Installation Guide

tire carriage

INSTALLATION

Dyno Installation

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

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

remove the 1/4-inch screws. For dynos with serial numbers lower than 2030152, Dynojet recommends using a hardened 5/32-inch hex driver (such as Snap-On FA5E). A standard allen key may round off in the shallow screw head.

5 Remove the tire stop, tire lock, and hardware from the middle of the dyno.

center panel

tire stop and tire lock

in middle

Figure 2-2: Remove the Center Panel

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-3

CHAPTER 2

Dyno Installation

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

Remove the drum cover and set aside.

7 Remove the two top screws securing each side drum cover to the dyno and set

aside.

top drum cover

side drum cover

Figure 2-3: Remove the Top Drum Cover

2-4

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

Dyno Installation

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

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.

RECORD

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

side drum cover

dyno number stamped

on frame

side drum cover

access holes in drum

bulkhead (only two

visible from this view)

Figure 2-4: Remove the Side Drum Covers

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-5

CHAPTER 2

Dyno Installation

REMOVING THE DYNO FROM THE CRATE

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.

bolt and washer

lifting eye

bolt and washer not

visible from this view

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

2-6

Model 200i and 250i Motorcycle Dynamometer Installation Guide

bolt and washer

lifting eye

bolt and washer

INSTALLATION

Dyno Installation

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

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.

lifting eye

cable routing

bracket

lifting eye

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.

loop strap

Figure 2-7: Lift the Dyno off the Crate

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-7

CHAPTER 2

Dyno Installation

ROUTING THE POWER CABLE

1 Locate the power cable inside the dyno. 2 Slide the strain relief on the power cable through the opening in the dyno frame. 3 Tighten the jam nut. 4 Hand tighten the knurled nut.

opening in

dyno frame

strain relief around

power cord

Figure 2-8: Route the Power Cable

jam nut

inside dyno

cut away view from

inside dyno

knurled nut

outside dyno

2-8

Model 200i and 250i Motorcycle Dynamometer Installation Guide

POSITIONING AND SECURING THE DYNO

1 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 15 for more information.

2 Secure the dyno to the floor in your dyno room.

Note: Skip this step if you will be installing the eddy current brake. Install the eddy current brake first, and then secure the dyno and the eddy current brake to the floor.

Dynojet recommends you secure your dyno to the floor in your dyno room using concrete anchors. You will want to mark and drill the holes in your concrete before adding any accessories or replacing the covers on your dyno.

2a Mark and drill holes. 2b Install the Red Head anchors according to the instructions in Appendix A.

MC118

INSTALLATION

Dyno Installation

mark and drill hole

mark and drill holes

hole not visible from

this view

Figure 2-9: Anchor Hole Placement

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-9

CHAPTER 2

Battery

BATTERY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The model 200i/250i 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.

INSTALLING 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.

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.

battery

Figure 2-10: Install the Battery

2-10

Model 200i and 250i Motorcycle Dynamometer Installation Guide

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

drum. 2 Install the pickup card to the bracket using two No. 8 screws. Do not tighten, the

card must be aligned first.

Note: If your dyno is equipped with an air brake, you will need to attach

compressed air and power to your dyno before you can turn the drum. Refer to

Figure 3-6 on page 3-7 for more information on attaching compressed air to your

dyno.

3 Align the optical pickup card with the tab on the dyno drum axle. Be sure the tab

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

help with alignment. 4 Once aligned, tighten the screws to secure the pickup card in place.

INSTALLATION

Pickup Card

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

tab on dyno

optical pickup

pickup card

top view of pickup card, optical

pickup, and tab on dyno

pickup card

bracket

tab on dyno

pickup card

Figure 2-11: Install the Pickup Card

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-11

CHAPTER 2

Eddy Current Brake

EDDY CURRENT BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 “Installing the Support Arm and Tray” on page 2-21.

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.

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

PARTS LIST

The following table lists all of the parts included in the Eddy Current Brake (P/N 63223700) Installation kit. Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support.

part number description quantity

21227107 Retarder Connector Plate (already installed) 2 21629403 Bar, Load Cell 1

36582034 Screw, 3/8”-16 x 1 1/4”, BH-FLNG 8

37620622 Woodruff Key, 3/8” x 1 3/8” 1 49950030 Temperature Sensor 1

61228400 Hood, Top, Retarder Module 1

63223700 Retarder Module 1 66411003 Theta-2 Controller 240V 1

2-12

Model 200i and 250i Motorcycle Dynamometer Installation Guide

UNPACKING THE EDDY CURRENT BRAKE

1 Remove the sides of the crate. 2 Remove the four screws securing the top cover and set aside. Remove the cover

and set aside. 3 Remove the hardware box and theta controller from the crate and verify the

hardware box contents using the parts list.

For more information on mounting the theta controller refer to page 2-20.

INSTALLATION

Eddy Current Brake

RECORD

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

top cover

eddy current brake number

Figure 2-12: Remove the Covers

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-13

CHAPTER 2

Eddy Current Brake

4 Remove the four bolts securing the brake to the crate. 5 Determine if the brake is to be mounted on the left or right side of your dyno.

Make the following adjustments to the eddy current brake only if you want

to mount the brake on the opposite side of the dyno that it is currently set

up for.

5a Move the coupler and key to the other side of the brake.

• To remove the key, use a punch and a hammer to apply pressure in the direction of the arrows shown in Figure 2-14.

5b Move the retarder connector plates to the other side of the brake. 5c Move the temperature sensor to the other side of the brake.

front of dyno

retarder

connector plates

eddy current brake set up for left side installation

Figure 2-13: Identifying Left or Right Side Brake Set Up

shaft

connector plates

apply force using

hammer and punch

temperature

sensor

coupler

retarder

key

eddy current brake set up for right side installation

apply force using

hammer and punch

2-14

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Figure 2-14: Remove the Key

INSTALLATION

Eddy Current Brake

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

Refer to Figure 2-4 on page 2-5. 7 Place the nylon loop strap through the lifting eyes on either side of the brake. 8 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. 9 Remove the eight bolts, washers, and nuts from the dyno frame where the

connector plates will attach. 10 Remove the starter brace, if present.

Note: Only remove the starter brace when installing the eddy current brake on

the left (starter) side of the dyno.

10a Remove the three bolts, washers, and nuts securing the starter brace and set

aside.

10b Remove the starter brace and set aside.

starter brace

EB141

lifting eye

remove bolts, washers, and

nuts from dyno frame

Figure 2-15: Move the Brake Next to the Dyno

line up panels

lifting eye

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-15

CHAPTER 2

Eddy Current Brake

INSTALLING THE EDDY CURRENT BRAKE

The eddy current brake comes with the coupler already installed on the brake shaft.

The eddy current brake can be installed on either side of your dyno. The air brake is located on the right side of the dyno. It is not necessary to remove the air brake regardless of which side of the dyno you are installing the eddy current brake: right or left.

Note: Safety requirements of your local country may require that both brakes are

installed. Be sure to follow the safety requirements specific to your country.

1 Insert the key into the keyway. 2 Use a c-clamp to press the key in, if necessary.

key

key way on dyno shaft

EB142

retarder connector plate

2-16

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Figure 2-16: Install the Key

INSTALLATION

Eddy Current Brake

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

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

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 retarder connector plate to the dyno frame using the four bolts,

washers, and nuts removed earlier. There is a retarder connector plate on either

side of the brake. Refer to Figure 2-17.

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 retarder connector plate bolts and nuts. 8 Secure the starter brace to the starter using the washer and nut removed earlier.

starter brace

retarder connector plate

EB143

three bolts not visible

from this view

Figure 2-17: Secure the Retarder Connector Plate and Starter Brace

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-17

CHAPTER 2

Eddy Current Brake

9 Secure the side panels on the eddy current brake to the panels on the dyno using

not visible from

this view

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

EB144

Figure 2-18: Secure the Side Panels to the Dyno

10 Replace the existing set screws on the coupler with the thread-lock set screws

provided. 11 Tighten the coupler set screws.

brake shaft

set screw

dyno shaft

Figure 2-19: Tighten the Set Screws

2-18

Model 200i and 250i Motorcycle Dynamometer Installation Guide

SECURING THE DRUM AND BRAKE MODULE TO THE FLOOR

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 placing the covers on your dyno.

1 Mark and drill the holes for the Red Head anchors. 2 Install the Red Head anchors according to the instructions in Appendix A. 3 Secure the eddy current brake to the ground using the same holes used to secure

the brake to the crate. Secure the dyno to the ground using the holes you drilled

previously.

MC122

INSTALLATION

Eddy Current Brake

mark and drill

holes for red head

anchors

mark and drill

holes for red

head anchors

mark and drill

holes for red

head anchors

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

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-19

CHAPTER 2

Eddy Current Brake

INSTALLING THE THETA CONTROLLER

The theta controller is the interface between the eddy current brake and the dyno electronics. You will only install the theta controller if you ordered an eddy current brake. You will route the cables to it later. The theta controller is shipped in the eddy current brake crate.

1 Verify the theta controller dip switch settings. Refer to Appendix C for more

information. 2 Secure the theta controller to the drum module bulkhead using four

8-32 x 3/8-inch screws as shown in Figure 2-21.

four 8-32 x 3/8"

screws

theta controller

EB146

Figure 2-21: Installing the Theta Controller

2-20

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

Support Arm and Monitor Tray

SUPPORT ARM AND MONITOR TRAY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

This articulated arm and platform supports the monitor, keyboard, and mouse in a convenient position for operation while seated on the motorcycle. The support arm can be mounted on either side of the dynamometer.

PARTS LIST

The following table lists all of the parts included in the Monitor Stand Installation kit. Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support.

part number description quantity

21229300 Monitor Arm Tray 1

32391064 Bushing, 1" x 2", 10 Gauge, Stl 3

35521420 Plastic Cap, 1.75" x 1/2", Black 4 36701100 Nut, 1/2-13, Hex 2

36801253 Screw, 1/2-13 x 1.5", Sh-Cap 2

36932100 Washer, 3/8", Splitlock, Stl 1 36942100 Washer, 1/2", Splitlock, Stl 2

36943100 Washer, 1/2", Flat, Stl 4

61329100 Monitor Arm 2

INSTALLING THE SUPPORT ARM AND TRAY

The support arm and monitor tray may be installed on either side of your dyno.

1 Remove the four 3/8-16 x 1/2-inch button-head flange screws from the dyno

where you plan to install the support arm. 2 Using an allen wrench, secure the support arm to the dyno frame with four

3/8-16 x 1/2-inch button-head flange screws you removed earlier. 3 Place a poly washer around the pin of the first arm and insert the arm into the

support arm. 4 Place a poly washer around the pin of the second arm and insert the arm into the

first arm. 5 Place a poly washer around the pin of the tray and insert the tray into the second

arm. 6 Insert a plastic cap in both ends of each arm. 7 Check for clearance between the monitor arm and motorcycle, walls, ceiling, etc.

Note: Dynojet does not recommend placing the computer CPU on the

monitor/keyboard tray since vibration can cause damage to the computer.

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-21

CHAPTER 2

Support Arm and Monitor Tray

poly washer

second arm

poly washer

first arm

poly washer

monitor tray

support arm

MA017

Figure 2-22: Install the Support Arm and Monitor Tray

2-22

Model 200i and 250i Motorcycle Dynamometer Installation Guide

DYNO ELECTRONICS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The standard dyno electronics package is comprised of four interconnected modules: Atmospheric Sensing Module, RPM Module, Dynamometer Input/Output Module, and the CPU Module. For more information about their function refer to your WinPEP 7 User Guide (P/N 98128104).

9-pin hand

system expansion

connector

held pendant

25-pin socket

RPM inductive

pickup socket

INSTALLATION

Dyno Electronics

atmospheric

sensing module

RPM module

input/output module

Figure 2-23: The Dyno Electronics

CPU module

power

9-pin RS-232 socket

3-pin power plug

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-23

CHAPTER 2

Dyno Electronics

The standard dyno electronics is located inside the dyno electronics enclosure which is already mounted to the dyno chassis as shown in Figure 2-24. Cables which you will route in the next steps are prewired to the dyno electronics or to the CPI. You will connect the free ends of the cables to the appropriate devices.

CPI

cables are pre-attached to the dyno electronics

located inside the

dyno electronics

enclosure

MC120

dyno electronics

enclosure

dyno electronics

enclosure

Figure 2-24: Location of Dyno Electronics

2-24

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

ROUTING CABLES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For the following instructions, the support arm and control panel are shown mounted on the right side of the dyno.

ROUTING THE PENDANT, RS232 COMPUTER CABLE, AND CONTROL PANEL CABLE

1 Remove the two screws securing the cable pass through cover (shown in

Figure 2-25) closest to the monitor support and set it aside. The cables you will

route will be coiled inside the chassis. 2 Route the pendant cable, 9-pin RS232 computer cable (P/N 42967090), and the

15-pin control panel cable, labelled Button Panel P1, from the dyno electronics

CPU Module through the cable pass through cover on the side closest to where

you installed your monitor arm. 3 Place a split snap bushing around the pendant cable and the RS232 cable and

secure them through one hole in the cable pass through cover. 4 Place a split snap bushing around the control panel cable and secure it in the

other hole on the cable pass through cover. The bushing should be around the

cable protective wrap. 5 Secure the cable pass through cover to the dyno with the two screws removed

earlier.

Routing Cables

pendant

route 9-pin RS232 cable

to your computer

15-pin control panel cable

labelled Button Panel P1

monitor support

cable pass through

cover

CP026

Figure 2-25: Route the Control Panel and Pendant Cables

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-25

CHAPTER 2

Routing Cables

6 Locate the control panel and ready it to connect the control panel cable. The

control panel ships in a separate container inside the dyno.

6a Remove the two nuts from the top of the cover and set aside.

6b Remove the screw on the top of the cover and set aside.

6c Remove the screw on the side of the cover and set aside.

6d Remove the four screws on the back of the cover and set aside.

6e Remove the control panel rear cover and set aside.

top screw

CP025

top nuts

back cover screws

Figure 2-26: Locate the Control Panel and Remove the Back Cover

rear screws

side screw

2-26

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

Routing Cables

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

panel box and through the cable tie. 8 Attach the control panel cable to the Button board.

control panel cable with

cable harness wrap

Figure 2-27: Attach the Control Panel Cable to the Button Board

9 Secure the rear cover to the control panel.

9a Replace the four screws on the back of the cover removed earlier.

9b Replace the screw on the top of the cover removed earlier.

9c Replace the screw on the side of the cover removed earlier.

9d Replace the two nuts on the top of the cover removed earlier.

access hole

cable tie

button board

Figure 2-28: Replace the Control Panel Rear Cover

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-27

CHAPTER 2

Routing Cables

10 Secure the control panel to the monitor tray using two 8-32-inch screws.

CP023

install control panel spindle if you did not purchase the monitor

tray

Note: If you did not order a monitor tray, install the control panel spindle to the back of your control panel using four 8-32 screws. Once installed, place the spindle on the control panel into the support arm where the monitor tray is shown in Figure 2-29.

control panel

CP027

Figure 2-29: Install the Control Panel

2-28

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

Routing Cables

11 Place the pendant in the slot provided on the control panel and route the cable

bundle along the support arms with service loops to allow movement.

12 If you plan to route your cables through a zip tube refer to “Zip Tube” on page 2-

44 and skip the following steps.

13 Attach the cable bundle with the cable clamps that are provided using 8-32-inch

screws. Adjust the service loops to allow for easy movement of the monitor arms without pulling on the cables.

You may want to route the RS232 connector to your computer part way up the support arm along with the control panel and pendant cables depending on where you your computer is located.

pendant

control panel

cable

CP028

cable clamps

Figure 2-30: Secure the Control Panel Cable to the Support Arm

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-29

CHAPTER 2

Routing Cables

ROUTING THE EDDY CURRENT BRAKE CABLES

With the center panel off, now is a good time to connect and route the theta controller cables. You will only have a theta controller if you installed the optional eddy current brake accessory, see Figure 2-21 on page 2-20.

1 Attach the input power cable (P/N 66952004) to the top of the theta controller. 2 Route the eddy current brake cable (P/N 66952003) from the eddy current brake

to the bottom of the theta controller.

3 Route the control cable from the theta controller out of the side of the dyno

chassis to the Breakout board through the hole in the CPI shown in Figure 2-31.

4 Route the temperature sensor cable from the eddy current brake through the air

hole in the drum bulkhead, through the opening on the side of the CPI, and over to the Breakout board.

Note: For more information on wiring the Breakout board refer to page 2-31.

air hole in drum

input power

bulkhead

EB148

theta controller

control cable

breakout board

Figure 2-31: Route the Eddy Current Brake Cables

eddy current brake cable

temperature sensor cable

2-30

Model 200i and 250i Motorcycle Dynamometer Installation Guide

WIRING THE BREAKOUT BOARD

1 Attach the temperature sensor cable to the Breakout board. The temperature

sensor cable has five wires which connect to the wiring block labeled TEMP. This cable was routed to the Breakout board on page 2-30.

• Green wire connects to G1 • White wire connects to W1

• Black wire connects to B1 • Red wire connects to R1

• Ground (shield) wire connects to S1

INSTALLATION

Routing Cables

2 Attach the theta controller cable to the Breakout board, if it is not already

connected. The theta controller cable has five wires which connect to the wiring block labeled LOAD CONTROL.

• Black wire connects to V- • Red wire connects to V+

• White wire connects to O+ • Green wire connects to O-

• Ground (shield) wire connects to SH

3 Attach the pickup; card cable to the Breakout board. The pickup card cable has

four wires which connect to the wiring block labeled DRUM 1.

• Red wire connects to R1 • Black wire connects to B1

• White wire connects to W1 • Ground (shield) wire connects to S1

4 Verify jumpers J1 and J2 are set either for the eddy current brake and air brake or

for the air brake only as shown in Figure 2-32.

If you have an eddy current brake and air brake, the air brake will only be activated when the dyno electronics power is turned off or the optional door interlock is installed and activated.

5 Close the power distribution enclosure door.

temp

eddy current brake only or eddy current brake and air

pickup card

J2 J1

brake with control panel

J1J2

load control

Figure 2-32: Wire the Breakout Board

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

air brake

only

2-31

CHAPTER 2

Routing Cables

ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES

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 3-42 and “Wheel Clamp” on page 3-47 for more information.

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 and wheel clamp cables through the opening in the

front of the dyno.

route cables

through

cable pass through

cover

Figure 2-33: Remove the Cable Pass Through Cover

2-32

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

Routing Cables

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

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.

cable pass through

cover

WC012

3-pin power carriage cable

Figure 2-34: Routing Wheel Clamp and Power Carriage Cables

2-pin wheel clamp cable

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-33

CHAPTER 2

Tire Carriage Installation

TIRE CARRIAGE INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. If you ordered the extended wheel carriage accessory, refer to “Installing the Extended Carriage Support Bracket” on page 3-31 and install it at this time.

The tire carriage is fastened to the bottom of the crate next to the dyno. Refer to step 2 on page 2-2 for instructions on removing the tire carriage from the crate.

If you do not have the standard tire carriage with the bearing bracket, refer to Appendix D for instructions on installing the standard tire carriage—discontinued.

Note: Before replacing the center panel and installing the tire carriage install the

air hose, the EEC Kit, the door safety switch, and any additional accessories you

may have ordered. Refer to the appropriate sections of this manual for installation

instructions.

1 Replace the center panel using the six 1/4-inch screws you removed. See Figure 2-

2 on page 2-3. 2 Install the three carriage clamps and shims using two 5/16-inch bolts and washers

each. 3 Install the nut block and shim using two 5/16-inch bolts and washers.

carriage clamp

nut block

shim

DC030

Figure 2-35: Install the Carriage Clamps and Nut Block

2-34

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

Tire Carriage Installation

4 Remove the four 1/4 x 20-inch button-head screws securing the bearing bracket. 5 Remove the bearing bracket and the carriage screw.

carriage

screw

Figure 2-36: Remove the Bearing Bracket and Carriage Screw

screw

bearing bracket

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-35

CHAPTER 2

Tire Carriage Installation

6 Starting from the back of the dyno, slide the carriage under the carriage clamps. 7 Slide the carriage screw and the bearing bracket toward the nut block until the

carriage screw is touching the nut block. 8 Slide the hand crank onto the end of the carriage screw. 9 Secure the hand crank to the screw shaft by tightening the set screw using a

5/32-inch allen wrench. 10 Using the hand crank, screw the carriage through the nut block and into the

screw support bracket. 11 Secure the bearing bracket to the carriage using four 1/4-20 x 1/2-inch

button-head flange bolts removed earlier.

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

page 3-42 for installation instructions.

carriage

nut block

hand crank

DC031

carriage screw

bearing bracket

Figure 2-37: Install the Tire Carriage and Secure the Hand Crank

2-36

Model 200i and 250i Motorcycle Dynamometer Installation Guide

tire stop

INSTALLATION

Tire Carriage Installation

12 Secure the tire stop 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 3-47 for installation instructions.

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

bolts.

tire lock

DC032

Figure 2-38: Install the Tire Stop and Tire Lock

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-37

CHAPTER 2

Drum Side and Top Covers

DRUM SIDE AND TOP COVERS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before replacing the covers, be sure to install the battery, pickup card, eddy current brake, and any accessories you may have purchased with your dyno.

Refer to Chapter 3 for accessory installation instructions.

1 Secure each side drum cover to the dyno using six of the screws you removed

earlier.

side drum cover

Figure 2-39: Replace the Side Drum Covers

2-38

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

Drum Side and Top Covers

2 Secure the top of the side drum covers with the screws you removed earlier. 3 Refer to Appendix D and install and adjust the finger guards if they are required in

your location. 4 Secure the top drum cover to the dyno using the eight screws removed earlier.

top drum cover

MC047

Figure 2-40: Replace the Top Drum Cover

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-39

CHAPTER 2

Ramp Bracket

RAMP BRACKET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

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.

ramp lip

ramp bracket

24 inches

Figure 2-41: Mark and Drill Ramp Bracket Holes

2-40

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLATION

Ramp Bracket

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

washers and nuts.

Figure 2-42: 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 2-43: Secure the Bracket to the Drum Cover

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-41

CHAPTER 2

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 2-44: Place the Ramp on the Dyno

2-42

Model 200i and 250i Motorcycle Dynamometer Installation Guide

GROUND HOOKS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

You may wish to install additional ground hooks (included with your dyno) for securing the motorcycle. Use the following instructions as a guide in placing your ground hooks.

1 Locate each ground hook approximately 96.5 cm (38 inches) from the front of the

dyno and approximately 20 cm (8 inches) from the side of the dyno

(approximately 152.40 cm, 60 inches, apart). 2 Using the ground hooks as a pattern, install the Red Head anchors using the

hardware included with the ground hook kit. Install the Red Head anchors

according to the instructions in Appendix A.

approx. 152.40 cm (60 in.)

INSTALLATION

Ground Hooks

approx.

20 cm

(8 in.)

approx. 96.5 cm (38 in.)

Figure 2-45: Ground Hooks

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

2-43

CHAPTER 2

Zip Tube

ZIP TUBE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The zip tube encases the multiple cables running to the control panel. You will need to use the cable wrap tool (P/N 16510001) to insert the cables into the 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

cable(s)

cable holder

guide body

end of cables

Figure 2-46: 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.

guide body

zip tube

cable wrap tool

Figure 2-47: Secure the Cable(s) Into the Zip Tube

2-44

Model 200i and 250i Motorcycle Dynamometer Installation Guide

end of cables

C HAPTER

CCESSORIES

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 Specialist’s at 1-800-992-3525 for pricing and availability.

Installation instructions for some of these options can be found in this chapter. Complete installation instruction manuals may also be found by browsing the Manuals folder on your WinPEP installation CD.

This chapter is divided into the following categories:

• Main Dyno Power, page 3-2

• Removing and Replacing Dyno and Drum Covers, page 3-3

•Air Brake, page 3-7

• Air Pump and Filter Assembly, page 3-21

• Extended Carriage, page 3-28

• High Pressure Blower, page 3-38

• Power Carriage, page 3-42

• Wheel Clamp, page 3-47

• Final Adjustments and Tests, page 3-49

Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-1

CHAPTER 3

Main Dyno Power

MAIN DYNO POWER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 breaker to turn power on and off to the dyno.

The main 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.

power plug

main breaker

Figure 3-1: Main Dyno Power

3-2

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Remove and Replace Dyno and Drum Covers

REMOVE AND REPLACE DYNO AND DRUM COVERS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

You will need to remove and replace the drum top and side covers along with the dyno center panel to access many of the accessory areas. Refer to the following instructions.

REMOVING THE DRUM TOP AND SIDE COVERS

1 Turn off the dyno and disconnect the AC power cord from its power source. Refer

page 3-2. 2 Remove the eight screws securing the top drum cover to the dyno and set aside.

Remove the drum cover. 3 Remove the two 1/4-20 x 5/8-inch pan head screws securing the top of each side

drum cover to the dyno and set aside.

top drum cover

ACCESSORIES

side drum cover

Figure 3-2: Remove the Top Drum Cover

side drum cover

MC047A

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-3

CHAPTER 3

Remove and Replace Dyno and Drum Covers

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

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

Note: For clarity, only the removal of the right side drum cover is shown.

right side drum cover

side screw

Figure 3-3: Remove the Side Drum Covers

3-4

Model 200i and 250i Motorcycle Dynamometer Installation Guide

REMOVING THE CENTER PANEL

1 Remove the four 1/4-20 x 5/8-inch pan head screws securing the bearing bracket

to the tire carriage and set aside. 2 Using the hand crank, unscrew the bearing bracket and the carriage screw and set

aside. 3 Remove the tire carriage by sliding the carriage under the carriage clamps toward

the back of the dyno and set aside.

ACCESSORIES

Remove and Replace Dyno and Drum Covers

hand crank

carriage screw

screws

bearing bracket

tire carriage

carriage clamp

Figure 3-4: Remove the Tire Carriage

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-5

CHAPTER 3

Remove and Replace Dyno and Drum Covers

4 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps

and shims and set aside.

5 Remove the three carriage clamps and shims and set aside.

6 Remove the two 5/16-inch bolts and washers securing the nut block and shim and

set aside.

7 Remove the nut block and shim and set aside.

8 Remove the six 1/4-20 x 5/8-inch pan head screws securing the center panel to the

dyno carriage and set aside. 9 Remove the center panel and set aside.

carriage clamp

shim

bolt

washer

nut block

screw

shim

MC124

center panel

Figure 3-5: Remove the Center Panel

3-6

Model 200i and 250i Motorcycle Dynamometer Installation Guide

AIR BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The air brake 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.

connect shop air supply

ACCESSORIES

Air Brake

Figure 3-6: Connect Your Shop Air Supply

PARTS LIST

The following table lists all of the parts included in the Air Brake (P/N 63920005) Installation kit. Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support.

part number description quantity

21222201 Brake Caliper Stop 1

21222601 Brake Adjusting Shim 1 21622201 Brake Bracket 1

32904080 Hairpin Cotter, 7/16-3/4” shaft size 3

32920128 Clevis Pin, 5/8 x 4” 2 36488100 Nut, 3/8-16, Nylock 1

36581270 Bolt, 3/8-16 x 3/4”, with Taper lock 2

36585670 Bolt, 3/8-16 x 3-1/2”, Hex 1 36820840 Bolt, 5/8-11 x 1, Hex 2

36952100 Washer, 5/8”, splitlock, stl 2

37620844 Woodruff Key, 1/2 x 2-3/4”, #1622-1 1 63920004 Air Brake Assembly 1

63990002 Rotor/Taper Lock Assembly with Hub and Key 1

BR102-055 Brake Spring 1

DM150-002-007 Washer, 5/16”, Flat 3

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-7

CHAPTER 3

Air Brake

ROUTING THE AIR BRAKE CABLE AND AIR HOSE

1 Open the CPI front panel to access the breakers and Breakout board. 2 Route the air brake cable from the air brake solenoid to the CPI.

Note: The CPI end of the air brake cable splits in two.

3 Connect the cable with the two black wires to the Breakout board wiring block

labeled BRAKE. 4 Attach the 4-pin connector to port P7 on the CPI board.

AB084

P7 on the

CPI board

brake wiring block

on the breakout board

Figure 3-7: Route the Air Brake Cable

3-8

Model 200i and 250i Motorcycle Dynamometer Installation Guide

ACCESSORIES

Air Brake

5 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. 6 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.

bulkhead fitting

air hose

access hole

air brake

Figure 3-8: Connect the Air Hose

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-9

CHAPTER 3

Air Brake

INSTALLING THE EMERGENCY STOP STICKER

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.

top screw

top nuts

side screw

rear screws

Figure 3-9: Remove the Control Panel Rear Cover

3-10

Model 200i and 250i Motorcycle Dynamometer Installation Guide

screw

ACCESSORIES

Air Brake

2 Remove the Button board.

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

set aside.

2b Remove the Button board and set aside.

button board

Figure 3-10: Remove the Button Board

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

switch body aside.

switch body nut

Figure 3-11: Remove the Switch Body

switch bod

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-11

CHAPTER 3

Air Brake

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

place emergency stop

sticker here

Figure 3-12: Place the Emergency Stop Sticker

3-12

Model 200i and 250i Motorcycle Dynamometer Installation Guide

ACCESSORIES

Air Brake

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

earlier.

switch body

switch body nut

control panel

Figure 3-13: Replace the Emergency Stop Button

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

earlier.

button board

screw

Figure 3-14: Secure the Button Board

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-13

CHAPTER 3

Air Brake

rear screws

7 Secure the rear cover to the control panel.

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 removed from the top of the cover removed earlier.

top screw

top nuts

side screw

Figure 3-15: 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 page 3-20 for instructions on adjusting the brake pad clearance.

3-14

Model 200i and 250i Motorcycle Dynamometer Installation Guide

CHANGING THE BRAKE PADS

To prevent possible injury, open the CPI door and set the main breaker to the off position and unplug the dyno. Refer to Figure 3-1 for breaker location.

1 Remove the top and right side covers from the dyno. Refer to page 3-3. 2 For safety, apply the brake and disconnect the air supply at the front of the dyno.

Refer to Figure 3-6 on page 3-7. 3 Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor.

ACCESSORIES

Air Brake

outboard brake pad

remove hairpin cotter

adjust castle nut

Figure 3-16: Loosen the Castle Nut

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-15

CHAPTER 3

Air Brake

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

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.

bolt

nut, washer, and spring

Figure 3-17: Remove the Brake Spring

bolt

nut, washer,

and spring

3-16

Model 200i and 250i Motorcycle Dynamometer Installation Guide

ACCESSORIES

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

brake bracket and remove the brake caliper stop.

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

brake caliper stop

brake bracket

Air Brake

Figure 3-18: Remove the Brake Caliper Stop

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

air brake assembly.

hairpin cotter

Figure 3-19: Remove the Bottom Hairpin Cotter

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

bottom clevis pin

3-17

CHAPTER 3

Air Brake

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

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.

top hairpin cotter

Figure 3-20: Remove the Bottom Pin and the Top Hairpin Cotter

9 Remove the top clevis pin.

top clevis pin

bottom clevis pin

Figure 3-21: Remove the Top Clevis Pin

3-18

Model 200i and 250i Motorcycle Dynamometer Installation Guide

top clevis pin

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

Figure 3-22: Remove the Brake Assembly

ACCESSORIES

Air Brake

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 3-22. 14 Replace the top and bottom clevis pins and secure with the hairpin cotters

removed earlier. Refer to Figure 3-19, Figure 3-20, and Figure 3-21. 15 Using two bolts and two washers, secure the brake caliper stop to the brake

bracket. Refer to Figure 3-18. 16 Secure the spring using the bolt, washer, and nut you removed earlier. Refer to

Figure 3-17. 17 Tighten the castle nut and replace the hair pin cotter. Refer to Figure 3-16. 18 Adjust the brake pad clearance. Refer to page 3-20 for complete instructions. 19 Replace the top and right side covers. Refer to page 3-3. 20 Connect your shop air.

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-19

CHAPTER 3

Air Brake

ADJUSTING THE BRAKE PAD CLEARANCE

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. Use the following steps to adjust the clearance.

1 Loosen the brake caliper stop bolts. 2 Insert the brake adjusting shim between the inboard brake pad and the brake

rotor. Refer to Figure 3-23. 3 Remove the hairpin cotter and hand tighten the castle nut on the caliper assembly

to clamp the brake pads against the rotor and shim. Refer to Figure 3-16 for

hairpin and castle nut location. 4 Tighten the brake caliper stop bolts. 5 Loosen the castle nut and remove the shim. 6 Adjust the clearance between the outboard brake pad and rotor. Loosen the castle

nut to increase the clearance.

There should be equal space on both sides of the rotor.

7 Replace the hair pin cotter in the castle nut.

Note: Cycle the brake to verify the brake pads release far enough so they do not

touch the rotor. If the pads touch the rotor during a run, the information

provided by the dyno will be inaccurate.

brake adjusting shim

Figure 3-23: Adjust Brake Pad Clearance

rotor

inboard brake pad

brake caliper stop bolts

3-20

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Air Pump and Filter Assembly

AIR PUMP AND FILTER ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refer to the Air Fuel Ratio Module Installation and User Guide (P/N 98295110) for proper operating and maintenance procedures. Refer to the Flow Meter User Guide (P/N 98129104) to test your air pump for accuracy. Failure to follow proper procedures may result in inaccurate data or damage to the equipment. These manuals can be found on your WinPEP CD or at www.dynojet.com.

Note: The Air Pump Assembly has a twelve month warranty.

• Dynojet recommends running the pump between dyno runs to help reduce the

chance of moisture contamination on the sensor.

• Remember to empty the exhaust collection bottles regularly.

• Leaks in the system will result in erroneous readings. Verify there are no cracks or

holes in the hoses and filter bowl. Verify the sensor is seated properly in the sensor block.

• Do not allow the filter bowl to fill with water during operation. Refer to the Air Fuel

Ratio Module Installation and User Guide for filter bowl information.

• Before turning the pump on, verify there is no water in the filter bowl. Always

empty the bowl before turning the pump on.

• Always allow the air pump to run after the dyno runs are complete to clear all water

from the filter bowl and allow the air pump to cool.

ACCESSORIES

Leaded racing fuels and two-stroke applications will contaminate the sensor and dramatically shorten its service life.

The sensor is not covered by a warranty. Be sure to read and understand the Air Fuel Ratio Module manuals.

Running the pump with the filter clogged, hose kinked, or filter removed will damage the pump and void the warranty.

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-21

CHAPTER 3

Air Pump and Filter Assembly

PARTS LIST

The following table lists all of the parts included in the Air Pump and Filter Assembly (P/N 64193009 Domestic or P/N 64193010 European) Installation kit. Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support.

part number description quantity

21125500 Filter and Sensor Housing 1

21626204 Pump Bracket 1 21696204 Pump Bottle Bracket 1

31991331 1/2” Diameter Rubber Hose 2

34420001 Filter Assembly 1 34491000 Filter Kit Replacement 5

39460210 Drip Bottle, Clear, Plastic 2

43310600 Grommet, 7/16” ID x 3/4” OD 2 64193050

or 64193051

Pump Assembly Replacement, 120V or Pump Assembly Replacement, 240V

lower bolts,

washers, and nuts

INSTALLING THE FILTER AND PUMP ASSEMBLIES

1 Remove the cover from the right side of the dyno. Refer to “Remove and Replace

Dyno and Drum Covers” on page 3-3. 2 Remove the four 1/4-inch screws securing the air fuel ratio (AFR) blanking plate to

the dyno and remove the plate. Set the screws aside, they will be used later. 3 Remove the lower two 3/8-inch bolts, washers, and nuts from the lower right

corner of the rear of the dyno and set aside to be used later.

blanking plate

Figure 3-24: Remove the Blanking Plate

3-22

Model 200i and 250i Motorcycle Dynamometer Installation Guide

ACCESSORIES

Air Pump and Filter Assembly

4 Install the filter assembly with the four 1/4-inch screws removed in step two.

filter assembly

Figure 3-25: Install the Filter Assembly

5 Install the pump assembly and exhaust bottle bracket using the two 3/8-inch bolts

removed in step 3.

exhaust bottle bracket

pump assembly

Figure 3-26: Install the Pump Assembly

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-23

CHAPTER 3

Air Pump and Filter Assembly

1/4-inch inlet hose

6 Connect the 1/4-inch inlet hose and the 1/8-inch inlet hose.

1/8-inch inlet hose

Figure 3-27: Connect the Inlet Hoses

7 Install two grommets and the outlet hoses as shown in Figure 3-28. 8 Install the exhaust bottles and insert the outlet hoses into the bottles.

exhaust bottles

outlet hoses

grommets

Figure 3-28: Install the Exhaust Bottles, Hoses, and Grommets

3-24

Model 200i and 250i Motorcycle Dynamometer Installation Guide

sensor

ACCESSORIES

Air Pump and Filter Assembly

9 Attach the sensor to the sensor block. 10 Attach the sensor cable to the corresponding cable from the inside back panel of

the dyno.

sensor cable

back view of filter assembly

Figure 3-29: Install the Sensor

11 Locate the wiring harness coming from the switch at the bottom of the filter

assembly. This wiring harness has two connectors. One connector attaches to the

pump while the other attaches to the dyno.

11a Attach the female four-pin connector to the pump cable.

11b Attach the male four-prong connector to the grey cable from the dyno. This

cable is located on the inside back panel of the dyno.

12 Replace the right side drum cover. Refer to “Main Dyno Power” on page 3-2.

CLEANING THE FILTER ASSEMBLY

Refer to the Air Fuel Ratio Module Installation and User Guide for detailed filter assembly cleaning procedures. Failure to follow proper procedures may result in inaccurate data or damage to the equipment. This manual can be found on your WinPEP CD or at www.dynojet.com.

If cleaning the filter does not result in free air flow, replace the filter. Be sure to check for other restrictions in the system.

Note: A clogged filter may cause erroneous readings or slow response. Clean the

filter daily or more often depending on usage.

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-25

CHAPTER 3

Air Pump and Filter Assembly

PUMP HEAD MAINTENANCE

Depending on usage, the pump will need periodic maintenance. Use the following instructions to remove the pump from the dyno. Once removed, refer to the Air Fuel Ratio Module Installation and User Guide for detailed pump head maintenance procedures.

To prevent possible injury, open the CPI door and set the main breaker to the off position and unplug the dyno. Refer to Figure 3-1 for breaker location.

1 Remove the exhaust collection bottles from the bracket. 2 Disconnect the outlet hoses from the pump.

outlet hoses

exhaust

collection bottles

1/4-inch inlet hose

Figure 3-30: Remove the Exhaust Bottles and Hoses

3 Disconnect the 1/4-inch inlet hose and the 1/8-inch inlet hose.

1/8-inch inlet hose

Figure 3-31: Disconnect the Inlet Hoses

3-26

Model 200i and 250i Motorcycle Dynamometer Installation Guide

ACCESSORIES

Air Pump and Filter Assembly

4 Remove the two 3/8-inch bolts securing the bracket to the pump assembly and set

the bolts and bracket aside. 5 Remove the pump assembly.

bottle bracket

pump assembly

Figure 3-32: Remove the Pump Assembly

6 Remove the four screws securing the pump to the bracket and set aside. 7 Remove the pump from the bracket.

pump

bracket

Figure 3-33: Remove the Pump from Bracket

8 Refer to the Air Fuel Ratio Module Installation and User Guide for detailed pump

head maintenance procedures. Failure to follow proper procedures may result in

inaccurate data or damage to the equipment. This manual can be found on your

WinPEP CD or at www.dynojet.com.

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-27

CHAPTER 3

Extended Carriage

EXTENDED CARRIAGE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The extended carriage option increases the maximum wheel base (measured from the front of the front wheel to the center of the rear wheel) from 84 inches to 101 inches for testing raked cruisers and drag bikes.

If you do not have the extended tire carriage with the bearing bracket, refer to Appendix D for instructions on installing the extended tire carriage—discontinued.

To prevent possible injury, open the CPI door and set the main breaker to the off position and unplug the dyno. Refer to Figure 3-1 on page 3-2 for breaker location.

PARTS LIST

The following table lists all of the parts included in the Extended Carriage (P/N 71323003) Installation kit. Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support.

part number description quantity

21224105 Carriage Clamp Spacer 4 21224106 Nut Driver Spacer 2

21624700 Extended Carriage Strap 1

36580434 Bolt, 3/8-16 x 1/2", Button-head, Flange, Allen 4 36560836 Screw, 1/4-20 x 1/2", Button-head, Flange 6

36561670 Bolt, 1/4-20 x 1" Hexagonal 2

63310901 Tire Lock Assembly with Stickers 1 71323003 Extended Carriage Assembly 1

DM150-002-003 Bolt, 5/16 x 1.5" 4

DM150-002-004 Washer, 5/16", Lock 4 DM150-002-007 Washer, 5/16", Flat 2

DM150-002-008 Nut, 5/16" 6

DM150-016-004 Carriage Screw Bearing 1 DM150-016-005 Carriage Screw 1

DM150-016-007 Carriage Screw Support Bracket 1

DM150-053 Bolt, 5/16 x 1" 4 EXT100-207 Extended Carriage Support Bracket 1

The following part numbers are not included with the extended tire carriage

63310902 Tire Stop with Stickers and Strap - Yellow 1 DM150-016-006 Carriage Hand Wheel 1

3-28

Model 200i and 250i Motorcycle Dynamometer Installation Guide

REMOVING THE STANDARD TIRE CARRIAGE

If you have already installed the standard tire carriage, use the following steps to remove it.

1 Remove the four 1/4-20 x 5/8-inch pan head screws securing the bearing bracket

to the tire carriage and set aside. 2 Using the hand crank, unscrew the bearing bracket and the carriage screw and set

aside. 3 Remove the tire carriage by sliding the carriage under the carriage clamps toward

the back of the dyno and set aside.

carriage clamp

ACCESSORIES

Extended Carriage

tire carriage

hand crank

carriage screw

screws

bearing bracket

Figure 3-34: Remove the Tire Carriage

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-29

CHAPTER 3

Extended Carriage

bolt

washer

nut block and shim

4 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps

and shims and set aside.

5 Remove the three carriage clamps and shims and set aside. 6 Remove the two 5/16-inch bolts and washers securing the nut block and shim and

set aside. 7 Remove the nut block and shim and set aside.

carriage clamp

and shim

Figure 3-35: Remove the Tire Carriage, Nut Block, and Clamps

3-30

Model 200i and 250i Motorcycle Dynamometer Installation Guide

INSTALLING THE EXTENDED CARRIAGE SUPPORT BRACKET

1 Loosely attach the extended carriage support bracket to the front of the dyno

using six 3/8-16 x 1/2-inch button-head flange allen bolts. 2 Using a straight edge, line the top of the support bracket with the top of the dyno

chassis. 3 Tighten all six screws.

extended carriage

support bracket

ACCESSORIES

Extended Carriage

Figure 3-36: Install the Extended Carriage Support Bracket

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-31

CHAPTER 3

Extended Carriage

4 Secure the extended carriage strap to the dyno using two 5/16 x 1-inch bolts and

two 5/16-inch lock washers.

Note: If your support bracket does not have holes, use the strap as a template to

drill them.

bolt

lock washer

strap

Figure 3-37: Secure the Strap to the Dyno

5 Secure the strap to the support bracket using two 5/16 x 1-inch bolts,

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

bolt

lock washer

strap

support

bracket

nut

Figure 3-38: Secure the Strap to the Support Bracket

flat washer

3-32

Model 200i and 250i Motorcycle Dynamometer Installation Guide

ACCESSORIES

Extended Carriage

6 Using the original shim and the large shim included with the kit, attach the nut

block to the front of the extended carriage support bracket using two

5/16 x 1 1/2-inch bolts, the flat washers you removed earlier, two 5/16-inch lock

washers, and two 5/16-inch nuts. 7 Using the original shim and the small shim included with the kit, attach the

carriage clamp to the front of the extended carriage support bracket using two

5/16 x 1 1/2-inch bolts, the flat washers you removed earlier, two 5/16-inch lock

washers, and two 5/16-inch nuts.

bolt

lock washer

nut block

extended carriage

support bracket

flat washer

nut

carriage clamp

TC046

Figure 3-39: Install the Nut Block and Front Clamp

Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide

3-33

CHAPTER 3

Extended Carriage

INSTALLING THE EXTENDED CARRIAGE

1 Remove the four 1/4 x 20-inch button-head screws securing the bearing bracket to

the carriage. 2 Remove the bearing bracket and the carriage screw.

carriage screw

screw

bearing bracket

Figure 3-40: Remove the Bearing Bracket and Carriage Screw

3-34

Model 200i and 250i Motorcycle Dynamometer Installation Guide

Dynojet 250i User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Dynamometer Specifications and Requirements

Model 200i Motorcycle Dynamometer

Model 250i Motorcycle Dynamometer

Dyno Installation

Battery

PICKUP CARD

Eddy Current Brake

Support Arm and Monitor Tray

DYNO ELECTRONICS

ROUTING CABLES

Tire Carriage Installation

Drum Side and Top Covers

Ramp Bracket

GROUND HOOKS

Zip Tube

Main Dyno Power

Remove and Replace Dyno and Drum Covers

AIR BRAKE

Air Pump and Filter Assembly

Extended Carriage