Dynojet 200: Installation Guide User Manual

©1993-2002 Dynojet Research, Inc. All Rights Reserved. 020329SDMotorcycleDynamometerInstallation Guide P/N 98220100Version 3Dynojet Research, Inc.2191

Motorcycle Dynamometer Installation GuideCHAPTER 1Introduction 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INTRODUCTIO

DYNO INSTALLATION AND SETUPIntroductionVersion 3 Motorcycle Dynamometer Installation Guide 1-3Industrial Noise Control, Inc.—Industrial Noise Cont

Motorcycle Dynamometer Installation GuideCHAPTER 1Introduction 1-4CONVENTIONS USED IN THIS MANUALThe conventions used in this manual are designed

DYNO INSTALLATION AND SETUPUncrate the DynoVersion 3 Motorcycle Dynamometer Installation Guide 1-5. . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 1Uncrate the Dyno 1-65 Remove the ramp bracket. The ramp bracket is attached to the bottom of the

DYNO INSTALLATION AND SETUPUncrate the DynoVersion 3 Motorcycle Dynamometer Installation Guide 1-7REMOVING THE DYNO FROM THE CRATEYou will need to

Motorcycle Dynamometer Installation GuideCHAPTER 1Uncrate the Dyno 1-87 Lift the dyno off the crate and move into position in your dyno room.8 Rem

DYNO INSTALLATION AND SETUPTire CarriageVersion 3 Motorcycle Dynamometer Installation Guide 1-9. . . . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 1Tire Carriage 1-105 Using the hand crank, screw the carriage through the nut block.6 Install the

DYNO INSTALLATION AND SETUPPickup CardVersion 3 Motorcycle Dynamometer Installation Guide 1-11. . . . . . . . . . . . . . . . . . . . . . . . . .

© 2002 Dynojet Research, Inc. CopyrightThis manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are res

Motorcycle Dynamometer Installation GuideCHAPTER 1Battery 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BATTERYA bike s

DYNO INSTALLATION AND SETUPDyno HoodVersion 3 Motorcycle Dynamometer Installation Guide 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 1Ramp Assembly 1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RAMP ASSE

DYNO INSTALLATION AND SETUPElectrical DiagramVersion 3 Motorcycle Dynamometer Installation Guide 1-15ELECTRICAL DIAGRAMFigure 1-18: Electrical Dia

Motorcycle Dynamometer Installation GuideCHAPTER 1Electrical Diagram 1-16

Motorcycle Dynamometer Installation Guide2-1C HAPTER2HARDWARE INSTALLATIONThis chapter contains the hardware installation specifications for the

Motorcycle Dynamometer Installation GuideCHAPTER 2Dynoware EX+ Hardware Stack 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HARDWARE INSTALLATIONDynoware EX+ Hardware StackVersion 3 Motorcycle Dynamometer Installation Guide 2-3RPM MODULEThe RPM module receives and proce

Motorcycle Dynamometer Installation GuideCHAPTER 2Dynoware EX+ Hardware Stack 2-4DYNAMOMETER INPUT/OUTPUT MODULEThe dynamometer input/output modul

HARDWARE INSTALLATIONDynoware EX+ Hardware StackVersion 3 Motorcycle Dynamometer Installation Guide 2-5CPU MODULEThe CPU module contains a 32-bit

Motorcycle Dynamometer Installation Guide iTABLE OF CONTENTSList of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 2Dynoware EX+ Hardware Stack 2-6CONNECTING THE DYNOWARE EX+ CABLESAttach the following cables usi

Motorcycle Dynamometer Installation Guide3-1C HAPTER3OPTIONAL ACCESSORIESThis chapter discusses the various optional accessories that are availab

Motorcycle Dynamometer Installation GuideCHAPTER 3Optional Accessories Overview 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONAL ACCESSORIESOptional Accessories OverviewVersion 3 Motorcycle Dynamometer Installation Guide 3-3Power Carriage—The power carriage replaces

Motorcycle Dynamometer Installation GuideCHAPTER 3Air Brake 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AIR BRAKEThe a

OPTIONAL ACCESSORIESAir BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-5PARTS LISTThe following table lists all of the parts included

Motorcycle Dynamometer Installation GuideCHAPTER 3Air Brake 3-6INSTALLING THE ROTOR/TAPER LOCK ASSEMBLYWhen upgrading from a manual brake, the rot

OPTIONAL ACCESSORIESAir BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-7INSTALLING THE CALIPER ASSEMBLY1 Tighten the two bolts shown i

Motorcycle Dynamometer Installation GuideCHAPTER 3Air Brake 3-84 Adjust the space between the brake pad and the rotor making sure the rotor is abl

OPTIONAL ACCESSORIESAir BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-92 Slide the master cylinder assembly through the holes in the

Motorcycle Dynamometer Installation GuideTABLE OF CONTENTS ii

Motorcycle Dynamometer Installation GuideCHAPTER 3Air Brake 3-10INSTALLING THE SPRING BOLT ASSEMBLY1 Push the mounting plate flush with the dyno c

OPTIONAL ACCESSORIESAir BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-11INSTALLING THE AIR HOSE1 Install the 1-inch grommet into the

Motorcycle Dynamometer Installation GuideCHAPTER 3Air Brake 3-124 Lift the front of the dyno high enough to access the cut out on the bottom side

OPTIONAL ACCESSORIESAir BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-13WIRING THE AIR VALVE ASSEMBLYThe wires that attach to the air

Motorcycle Dynamometer Installation GuideCHAPTER 3Air Brake 3-14WIRE SET UP 2This wire set up is used in newer dynos where the terminal strip is h

OPTIONAL ACCESSORIESAir BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-15FINAL ADJUSTMENTS AND TESTS1 Verify the dyno is set up proper

Motorcycle Dynamometer Installation GuideCHAPTER 3Air Brake 3-16AIR BRAKE ASSEMBLY SCHEMATICFigure 3-23: Air Brake Assembly Schematic

OPTIONAL ACCESSORIESDual FanVersion 3 Motorcycle Dynamometer Installation Guide 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 3Dual Fan 3-18MODIFYING THE TIRE STOPOlder dynos may not have the four holes on the tire stop nee

OPTIONAL ACCESSORIESDual FanVersion 3 Motorcycle Dynamometer Installation Guide 3-19INSTALLING THE EXTENSION ARM ASSEMBLYThe fan extension arm ass

Motorcycle Dynamometer Installation GuideiiiLIST OF FIGURESFigure 1-1: Custom Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 3Dual Fan 3-20INSTALLING THE FAN ASSEMBLIESRepeat the following steps for each fan assembly.1 Pla

OPTIONAL ACCESSORIESDual FanVersion 3 Motorcycle Dynamometer Installation Guide 3-21INSTALLING THE OUTLET BOXThe outlet box mounts to the main bra

Motorcycle Dynamometer Installation GuideCHAPTER 3Dual Fan 3-22MODIFYING THE EXTENSION ARM ASSEMBLY (FOR POWER CARRIAGE ONLY)When the fan assembly

OPTIONAL ACCESSORIESDual FanVersion 3 Motorcycle Dynamometer Installation Guide 3-234 Flip arm A over, place the poly washer on the stud, and inse

Motorcycle Dynamometer Installation GuideCHAPTER 3Extended Carriage 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EXTEN

OPTIONAL ACCESSORIESExtended CarriageVersion 3 Motorcycle Dynamometer Installation Guide 3-25REMOVING THE TIRE CARRIAGE1 Using a 5/32-inch allen w

Motorcycle Dynamometer Installation GuideCHAPTER 3Extended Carriage 3-26INSTALLING THE EXTENDED CARRIAGE SUPPORT BRACKET1 Remove the eight screws

OPTIONAL ACCESSORIESExtended CarriageVersion 3 Motorcycle Dynamometer Installation Guide 3-273 Using a straight edge, line the top of the support

Motorcycle Dynamometer Installation GuideCHAPTER 3Extended Carriage 3-28INSTALLING THE EXTENDED CARRIAGE1 Slide the extended carriage through the

OPTIONAL ACCESSORIESMechanical BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideLIST OF FIGURES ivFigure 3-6: Remove and Replace the Hood. . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 3Mechanical Brake 3-30INSTALLING THE ROTOR/TAPER LOCK ASSEMBLY1 Remove the hood. Refer to “Removi

OPTIONAL ACCESSORIESMechanical BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-31INSTALLING THE CALIPER ASSEMBLY1 Tighten the two bolts

Motorcycle Dynamometer Installation GuideCHAPTER 3Mechanical Brake 3-324 Adjust the space between the brake pad and the rotor making sure the roto

OPTIONAL ACCESSORIESMechanical BrakeVersion 3 Motorcycle Dynamometer Installation Guide 3-333 Remove the plunger from the pedal brake assembly. Sl

Motorcycle Dynamometer Installation GuideCHAPTER 3Monitor Arm 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MONITOR ARM

OPTIONAL ACCESSORIESMonitor ArmVersion 3 Motorcycle Dynamometer Installation Guide 3-35INSTALLING THE MONITOR ARM BRACKET1 Drill a 1/2-inch hole t

Motorcycle Dynamometer Installation GuideCHAPTER 3Monitor Arm 3-36INSTALLING THE ARMS AND TRAY1 Place a bushing on the pin of the first arm and in

OPTIONAL ACCESSORIESPower CarriageVersion 3 Motorcycle Dynamometer Installation Guide 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 3Power Carriage 3-382 Using a 5/32-inch allen wrench, loosen the two set screws in the lock colla

OPTIONAL ACCESSORIESPower CarriageVersion 3 Motorcycle Dynamometer Installation Guide 3-392 Slide the motor mount assembly and flange bearing, rem

LIST OF FIGURESVersion 3 Motorcycle Dynamometer Installation Guide vFigure 3-35: Install the Nut Block and Front Clamp. . . . . . . . . . . . . .

Motorcycle Dynamometer Installation GuideCHAPTER 3Power Carriage 3-405 Secure the aluminum cover with the two screws you removed earlier.6 Plug th

Motorcycle Dynamometer Installation GuideIndex-iINDEXAair brake 3-2, 3-4–3-15adjustments and tests 3-15air cylinder 3-8air hose 3-11air valve 3-1

Motorcycle Dynamometer Installation GuideINDEX Index-iiFfan assembly 3-20fat boy adapter 3-2Ggrease zerk 3-39Hhand crank 1-9hardware stack 2-2high

Version 3 Motorcycle Dynamometer Installation Guide Index-iiiTtechnical support 1-4tire carriage 1-9–1-10belleville washers 1-10carriage clamps 1-

Motorcycle Dynamometer Installation GuideLIST OF FIGURES vi

Motorcycle Dynamometer Installation Guide1-1C HAPTER1DYNO INSTALLATION AND SETUPThis document provides instructions for installing the Dynojet Mo