©1993-1999 Dynojet Research, Inc. All Rights Reserved.
Installation Guide for Snowmobile Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual, as well as 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 89031, USA.
Printed in USA.
Part Number: 98260100 Revision D (11/1999)
Document #98260100 1i
Contents
Chapter 1 ..............................................1 - 1
Setup and Maintenance
Uncrating the Dyno ................................................................1 - 1
Dyno Maintenance .................................................................1 - 7
Chapter 2 ..............................................2 - 1
Hardware Installation
DynoWare EX+........................................................................2 - 1
Atmospheric Sensing Module........................................................2 - 1
RPM Module............................................................................2 - 2
Dynamometer Input/Output Module
............................................... 2 -3
CPU Module...................................................................................................2 - 4
Connecting The DynoWare EX+............................................2 - 5
Chapter 3 ..............................................3 - 1
Optional Accessories Installation
Driver Carriage........................................................................3 - 1
Revision D 11/4/1999
1ii Document #98260100
Document#98260100 1 - 1
Chapter 1
Setup and Maintenance of the Sled Dyno
Uncrating the dyno
Step 1
Look for any external damage to the crate. If any
damage is present contact the carrier and Dynojet.
Step 2
Remove the top of the crate.
Step 3
Remove the sides of the crate.
Revision D 11/4/1999
1 - 2 Document #98260100
The crate will contain the following.
1 - box containing:
2 - (A) inside driver wheels and hubs
2 - (B) outside driver wheels and hubs
1 - (C) middle spacer
1 - (D) short (red) driver shaft
1 - (E) long (green) driver shaft
2 - (F) short spline shafts
2 - (G) long spline shafts
2 - (H) retainer clips and bolts
4 - (I) inside drive spacers (2 sets)
6 - (J) track tensioning guides (3 sets of 2)
1 - (K) shim pack (6 sets of 2)
1 - (L) track tensioning blocks
1 - (M) Yamaha tensioner
2 - (N) allen head bolts and lock washers
1 - (O) shaft extractor (3 pieces)
1 - (P) Yamaha middle spacer
2 - (Q) Yamaha inside drive spacers
2 - (R) Yamaha suspension adapters
1 - dynamometer guard (not shown)
1 - jack (not shown)
1 - lift handle (not shown)
1 - dynamometer
1 - bolt pack
1 - Brake Cover (not shown)
1 - Lid Extension (not shown)
A
G
B
C
D
E
F
H
M
L
I
K
J
N
O
R
Q
P
Document #98260100 1 - 3
Step 4
Remove all components except the dyno and
check the contents.
Step 5
Remove bolts holding down the dyno.
Install handle into receivers and secure with 1/4"
bolts. Raise the handle to engage the wheel so the
dyno will roll.
Step 6
To lift the dyno off the crate, use a continuous
loop strap and hook on all four corners of the
main frame (Refer to the picture on the next
page).
Important:
Loop the straps so that they cross at the
top.
Correct
Incorrect
1 - 4 Document #98260100
DO NOT LIFT THE DYNO BY THE ARMS !
Step 7
Install the jack with the pin and cotter keys on top
and the 3/8” bolt in the bottom.
Step 8
Install the brake cover, it attaches with (5) 1/4”
button head screws. Two screws of the front, and
three screws on the rear.
Document #98260100 1 - 5
Install the front (2) screws. These screws are
accessed from the inside of the brake cover.
(Leave the Screws Loose)
Install the (3) screws on the back of the Brake
Cover. (Leave the Screws Loose)
Brake
Cover
1 - 6 Document #98260100
Step 9
Fit the cover into position and check clearances.
The Lift Handle on the back of the dyno should
move freely without binding.
When everything f its well, you may tighten down
the (5) 1/4” button head screwss
Step 10
Install Lid Extension with (4) 1/4” button head
bolts.
Lid Extension
Document #98260100 1 - 7
Dyno Maintenance
The dyno should get a general inspection every 2
weeks depending on the number of runs made.
This inspection should include:
Checking all bolts to ensure they are tight.
Ensure the sprockets and driver assembly is
in good working condition.
Examine the plastic driver wheels to ensure that
they are in good shape and do not show
excessive wear.
The chain guards should be removed and the
chain tension checked every 300 runs. (Refer to
the pictures and the text below)
There is a red arrow on each of the arms. This
is the location at which the chain tension is
checked. Use a pull scale to apply 12 pounds on
the chain pulling the chain up. Measure from
the bottom inside of the chain guide to the top of
a link in the chain. The chain should be 1 3/
16
inches from the bottom of the guide.
1 - 8 Document #98260100
The cover should be removed every 300 runs
to ensure the brake is properly adjusted (see
next page) and to check the internal
components for wear.
Use the brake adjustment bolt on the left (shown
below) to adjust the Left side brake pad. Loosen
the lock nut and screw the adjuster bolt in so
that the clearance between the brake pad and
the disk is 0.0500". Tighten the lock nut. Do the
same to the right side. Check the brake fluid
and fill if necessary.
Brake Adjustment Screws
Left Right
Document #98226100 Master 2 - 1
Chapter 2
Hardware Installation
DynoWare EX+
The standard dynamometer electronics package is
comprised of 4 interconnected modules:
Atmospheric Sensing Module:
The atmospheric sensing module measures
absolute pressure, air temperature and relative
humidity. These measurements are used by
WinPEP to correct power and torque
measurements to standard atmospheric conditions
according to a DIN, SAE or other formula.
The green LED glows when the atmospheric
sensing module is receiving power.
The flashing amber LED indicates the module
processor is operating properly.
System Expansion Connector
Atmospheric Sensing Module
RPM Module
Dynamometer Input/Output
Module
CPU Module
Revision C 11/16/00
2 - 2 Master Document #982261002 - 2 Master Document #98226100
RPM Module:
The RPM module receives and processes signals
from up to 2 inductive pickups for measurement
of engine RPM. Each input has an automatic
gain circuit to compensate for a wide variance of
ignition systems.
The green LED glows when the RPM module is
receiving power.
The amber LED flashes when an RPM signal is
detected. A steady flash rate, proportional to
engine RPM, indicates a good RPM signal.
These connectors are the inputs for both primary
and secondary inductive pickup clips. Either
input may be used with a primary inductive
pickup or a secondary inductive pickup on a
single ended coil. Both inputs can be used for a
wasted spark ignition.
Document #98226100 Master 2 - 3Document #98226100 Master 2 - 3
Dynamometer Input/Output Module:
The dynamometer I/O module sends and receives
data from the dynamometer and the hand held
pendant. The module also contains a buzzer and
light which are activated when either the vehicle
or dynamometer speed limit is approached.
The green LED glows when the dynamometer
input/output module is receiving power.
The amber LED flashes proportionally to
dynamometer drum RPM.
This 25-pin receptacle connects to the shielded
cable from the dynamometer.
This 9-pin receptacle connects to the hand held
pendant which houses the button used to
Start/Stop acquiring data. The pendant may also
contain a brake switch.
2 - 4 Master Document #982261002 - 4 Master Document #98226100
CPU Module:
The CPU module contains a 32-bit processor
which acquires data from the expansion modules
and communicates to the main computer running
the WinPEP software. The processor queries the
expansion modules to determine their identity
and capabilities.
The green LED glows when the CPU module is
receiving power.
The blue LED is lighted when data from the
modules is being acquired and saved.
One of these connectors is used to communicate
to the main computer. The 9-pin receptacle (left)
connects to the PC’s RS-232 serial
communications port. The 8-pin modular
connector (right) provides communications
according to the RS-422/485 specification.
Document #98226100 Master 2 - 5Document #98226100 Master 2 - 5
CPU Module: ..... Continued
This connector provides a synchronization signal
to a 3rd-party data acquisition system.
This connector provides 12 Volt DC power to a
3rd-party data acquisition system.
This connector accepts 12 Volt DC power from a
power supply or battery. The adjacent LED
glows bright green when power is properly
connected.
When this switch is on, power is supplied to all
connected modules.
Connecting the DynoWare EX+
Use the cables that came in the DynoWare
package to make the following connections:
• 9-pin shielded serial cable between the RS-232
connector of the CPU Module and a free COM
(serial communications) port on the PC. A 9pin to 25-pin adapter may be required at the
PC.
• 25-pin shielded cable from the dynamometer to
the Dynamometer Input/Output Module.
• 9-pin connector from the hand held pendant to
the Dynamometer Input/Output Module.
• 3-pin plug from the power supply to the CPU
Module with its flat side facing down.
(Refer to the picture on the next page)
Note:
The DynoWare EX+ stack must be
mounted in your shop so as to be easily
seen while making dyno runs.
2 - 6 Master Document #982261002 - 6 Master Document #98226100
Remote Switch
Breakout Board to
DynoWare Cable
Cord from Power Supply
Primary Inductive Pickup Cable
(not shown)
Computer Serial Port Cable
Document # 98260100 3-1
Chapter 3
Optional Accessories Installation
Several optional accessories are available for the
Dynojet Dynamometer. Call Dynojet for more
information on these optional accessories.
Optional Accessories
Driver Carriage
This fully adjustable Carriage has several
benefits. First, this option allows a dyno owner to
hook to any conventionally driven snowmobile.
The OEM suspension can be removed and the
Driver Carriage will adjust to fit the stock
mounting holes.
Second, the Driver Carriage offers advantages
when extensive product development is being
done on the dyno. Some tracks are too tight to
install the standard Dynojet Driver Set at the
factory recommended tension. In this case, using
the Dynojet Driver Carriage offers quick and
easy installation to reduce set up times.
3-2 Document # 98260100
Contents
(A) - Driver Carriage Frame
(B) - Front Mount Assembly
(C) - Rear Mount Assembly
Driver Carriage Set up
Step 1
The pins on the Driver Carriage frame should be
retracted when you receive it. Fit the Front
Carriage Mount to the front of the frame and
release the pins.
The Front Carriage Mount should be oriented so
that it can touch the stop.
The Front Carriage Mount should not
be able to
swing out in front of the Carriage Frame!
A
BC
Front Carriage
Mount Stop
Document # 98260100 3-3
Step 2
Mount the Rear Carriage Mount to the Carriage
Frame with the (6) 3/8” allen head bolts. The
backing plates that the bolts thread into have a
left and right side.
The holes are offset to one side, this
is the side that should be closest to
the outside on the Carriage Frame.
Backing plates
Offset holes
towards outside
Offset holes
towards outside
Note: The Rear Carriage Mount can be mounted
in two different configurations depending
on your snowmobile. See next page for
applications.
Application #1
- Polaris
- Y amaha
- Ski Doo / Bombardier
- Arctic Cat
Rear Carriage Mount should oriented so that 4
out of the 6 holes are towards the front of the
carriage. (The triangular braces are facing
towards the Front Carriage Mount)
Application #2
- Fast M-10
- AD Boi vin
- Similar Designs to the above where additional
Front Carriage Mount clearance is needed.
Rear Carriage Mount should oriented so that 4
out of the 6 holes are towards the rear of the
carriage. (The triangular braces are facing
towards the Dynojet Driver Assembly (not
shown))
Step 3
Install the Driver Set in the Carriage Frame. The
process is the same as installing it in the sled’s
suspension rails. Refer to the video on installing
Driver Sets that was supplied with your dyno.
The spacing between the Driver Carriage rails is
8.5”, similar to setting up a Driver Set for a SkiDoo snowmobile.
3-4 Document # 98260100
Note: The spacing on the Driver Set for the
Driver Carriage stays consistent, even
when testing snowmobiles from different
manufacturers.
Document # 98260100 3-5
Installing the Driver Carriage
Step 1
Remove the rear suspension as per manufacturers
instructions.
Step 2
Due to the varying widths of tunnels, it will be
necessary to measure the width between the
suspension mounting holes.
Step 3
Using the measurements, you must lengthen or
shorten the adjustable rods on the Driver
Carriage.
Remove the adjustable rods by loosening the set
screw and “popping” them out with a punch. Be
careful that you don’t damage the threads on
the adjustable rods!
Front Carriage
Mount
Set Screw
3-6 Document # 98260100
Step 4
Now that you have the adjustable rods removed,
loosen the locking nuts on the rods.
Adjust the length on the rods equally on each
side (front / rear) to reflect the measurements you
took earlier.
Step 5
Reinstall the adjustable rods into the front and
rear Driver Carriage mounts and tighten the set
screw.
Rear Carriage
Mount
Document # 98260100 3-7
Step 6
Install the front Driver Carriage mount in the two
most forward (towards engine) holes in the
tunnel.
If there is a clearance issue, you will need to
remove the idler wheels from the Front Carriage
Mount.
Remove the snap rings and remove each idler
wheel. The idler wheels will need to be “pressed”
off.
Note: On some sleds, the Front Carriage Mount
idler wheels may interfere with the
snowmobile’s drivers. You will need to
test fit the Front Carriage Mount to each
sled and check the clearances.
Remove (2)
snap rings, (1)
from each side
Snap Ring
Pliers
3-8 Document # 98260100
Step 7
Retract the spring pins in the Driver Carriage,
and then position it in the front mount. Release
the spring pins when you have the holes lined up.
Step 8
Install the rear mount of the Driver Carriage to
the rear mounting holes on the tunnel.
Document # 98260100 3-9
Step 9
The track should be hanging loose at this point,
you will need to pre-tension the track with the
Driver Carriage.
Loosen the bolts that hold the rear mount on the
Driver Carriage.
Loosen (6) Bolts
(3 on each side)
3-10 Document # 98260100
Tighten the center adjuster bolt to pre-tension the
track.
Tighten the (6) bolts that hold the rear mount on
the Driver Carriage.
Step 10
The track should now be pre-tensioned, and the
Driver carriage should be secure.
Use the (2) adjuster bolts on the Driver Carriage
and tension the track to manufacturers
specifications.
Note: Do not use the center Driver Carriage
adjuster bolt to tension the track. This
is for rough adjustment purposes only !
Tighten (6) Bolts
(3 on each side)
Document # 98260100 3-11
Step 11
Reverse the procedure to remove the Driver
Carriage, and replace the suspension per
manufacturers instructions.
Warning: The Driver Carriage is designed for
dynamometer testing. Never attempt to
ride a snowmobile with the driver
carriage installed!
Warning: Never sit on the snowmobile
when the
Driver Carriage is installed, you will
damage it!
Note:
To maintain years of trouble free service,
clean the Driver Carriage at the end of
each day. Use “anti-seize”on the
channels to ensure smooth operation.
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