Dynojet 200iX Installation Manual
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Dynojet 200iX Installation Manual

Dynojet 200iX Installation Manual

Ground model motorcycle dynamometer
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Summary of Contents for Dynojet 200iX

  • Page 2 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...

  • Page 3: Table Of Contents

    Installing the Load Cell ..........2-22 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 4 Installing the Power Carriage ......... . 3-25 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 5 ..........5-13 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 6 Ground Hook Installation—Above Ground iXW Dyno ..... E-18 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 7 ............Index-i Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 9: Warnings

    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.
  • Page 10 To avoid ESD damage, always practice good ESD control precautions when servicing the dynamometer. Dynojet designs its dynamometers to be very tolerant of static shocks by the users, but the electronics are vulnerable when the electronics are exposed.
  • Page 11 Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically recommended in published user-repair instructions that you understand and have the skills to carry out. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 13: Chapter 1 Specifications And Operating Requirements

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

  • Page 14: Introduction

    XW I BOVE ROUND I NSTALLATION This appendix describes the procedures for installing the above ground iXW upgrade kit. ORQUE ALUES This appendix describes standard and metric torque values. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 15: Conventions Used In This Manual

    ECHNICAL UPPORT For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081. Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of the art technical support, on-line shopping, and press releases about our latest product lines.

  • Page 16: 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.

  • Page 17: Dynamometer Specifications And Requirements

    ATTERY EQUIREMENTS Your 200iX/250iX dyno is designed to carry a group 24 deep-cycle discharge series battery for operating the starter, power carriage, and optional wheel clamp. The typical dimensions for this 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).
  • Page 18 C H A P T E R 1 Dynamometer Specifications and Requirements Figure 1-1: Model 250iX Dyno Dimensions Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 19 Folding Ramp Option (iX Module) Model 250i Dyno Trike Adapter iX Drum Module Assembly Air Brake Option Air Pump Option (not shown) (not shown) Figure 1-2: Model 250iX Dyno with Accessories Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 20: Compressed Air Requirements

    1 free 10/100Mbps RJ45 Port on IP RJ45 Ethernet Port Router, Wireless, or Wired and Internet Access External Media CD Rom Drive CD Rom Drive Printer Printer, if prints or needed Color printer, if prints are needed Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 21: Drill And Drill Bit Requirements

    LECTRICAL EQUIREMENTS The Model 200iX/250iX dynamometers require a 240V - 30a single-phase electrical circuit for reliable and precise operation. No other loads should be plugged into these circuits and these circuits should be independent of the lighting in the dyno room.

  • Page 22: Grounding Requirements

    NTERNET CCESS 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.

  • Page 23: Dynoware Rt Electronics

    DynoWare RT electronics can be found in the Power Core Help. DynoWare RT eddy current main module brake driver air fuel ratio speed pickup module Figure 1-3: DynoWare RT Electronics Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 1-11...
  • Page 24 Do not press this button unless drum 2 speed inputs and Instructions instructed to do so by a Dynojet digital brake outputs. Technician. This button may need to be pressed to update the device. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 1-12...

  • Page 25: Network Connections

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

  • Page 27: Installation

    • Monitor Support and Tray, page 2-49 • Control Panel and Cable, page 2-50 • Final Adjustments and Tests, page 2-53 • Zip Tube, page 2-55 • Ground Hooks, page 2-56 • Ramp Bracket, page 2-57 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 28: Unpacking And Inspecting The Dyno

    UNPACKING AND INSPECTING THE 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...
  • Page 29 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. Remove the tire stop, tire lock, and hardware from the middle of the dyno.
  • Page 30 Remove the two top screws securing each side drum cover to the dyno and set aside. top drum cover side drum cover side drum cover D 038 Figure 2-3: Remove the Top Drum Cover Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 31 D 039 access holes in drum bulkhead (only two visible from this view) Figure 2-4: Remove the Side Drum Covers Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 32 P/N 43400000 pickup (2) P/N 76950201 secondary inductive  cable clamp (7) P/N 43428232 pickup (2) P/N 76950203 split snap busing (4) cable, wheel clamp P/N 43991080 P/N 76950307 optional accessory Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 33 CAN control adapter assembly P/N 76950807 P/N 64100008 optional accessory DynoWare RT main module cable, control panel P/N 66100016 P/N 76951501 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 34 P/N DM150-019-008 optional accessory see page 3-27 The following parts are included in the Grounding Kit P/N 76100015: grounding bracket cable, vehicle ground P/N 21600084 P/N 76950788 screw, 1/4-20 x 1/2" P/N 36560834 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 35 (1) washer, 5/16", flat (2) P/N 10111 P/N DM150-002-007 washer, 3/8", splitlock, steel bolt, 3/8-16 x 1", hex (2) (2) P/N DM150-019-012 P/N 36932100 anchor, redhead, 3/8" (2) P/N 37513200 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 36: Dyno Installation

    (2,500 lbs.) to lift the dyno off the crate and into position in your dyno room. You will also need a pair of straps capable of supporting 1,133.98 kg (2,500 lbs.) to attach to the dyno. Dynojet recommends using a single loop style strap. RECORD Be sure you record the dynamometer number on the inside cover of this manual.
  • Page 37 Note: While the dyno is supported by the forklift and before it is placed in your dyno room, the power cable must be routed through the front of the dyno. Figure 2-7: Lift the Dyno off the Crate Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-11...
  • Page 38 MC076A cut away view from inside dyno opening in dyno frame jam nut knurled nut inside dyno strain relief around outside dyno power cord Figure 2-8: Route the Power Cable Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-12...

  • Page 39: Battery

    Battery BATTERY The model 200iX/250iX dyno is designed to carry a group 24 deep-cycle discharge series battery for operating the starter, optional power carriage, and optional wheel clamp. The typical dimensions for this series of batteries are 27 cm long by 17 cm wide by 23 cm tall (10.625-inches by 6.75-inches by 9.125-inches).

  • Page 40: Pickup Card

    Figure 2-10: Install the Pickup Card Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-14...

  • Page 41: Eddy Current Brake

    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.
  • Page 42 CAN control, 15' P/N 37513200 P/N 76950791 see page 2-23 see page 2-32 installation tool, redhead bolt, 3/8-16 x 1", hex (2) anchor P/N DM150-019-012 P/N 37518200 see page 2-23 see page 2-23 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-16...
  • Page 43 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 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-17...
  • Page 44 Remove the eight bolts, washers, and nuts from the dyno frame where the connector plates will attach. line up panels lifting eye remove bolts, washers, and lifting eye nuts from dyno frame Figure 2-13: Move the Brake Next to the Dyno Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-18...

  • Page 45: Installing The Eddy Current Brake

    Insert the key into the keyway. Use a c-clamp to press the key in, if necessary. key way on dyno shaft connector plate Figure 2-14: Install the Key Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-19...
  • Page 46 Once aligned, tighten all connector plate bolts and nuts. connector plate EB240 three bolts not visible from this view Figure 2-15: Secure the Connector Plates Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-20...
  • Page 47 Replace the existing set screws on the driveline with the thread-lock set screws provided. 10 Tighten the driveline set screws. dyno shaft brake shaft set screw Figure 2-17: Tighten the Set Screws Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-21...

  • Page 48: Installing The Load Cell

    Secure the load cell to the mounting bracket using the two bolts and nuts removed earlier. install the load cell (the brake is not shown for clarity) PD229 Figure 2-19: Install the Load Cell Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-22...

  • Page 49: Secure The Dyno And Brake Module To The Floor

    Secure the Dyno and Brake Module to the Floor SECURE THE DYNO 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 adding any accessories or replacing the covers on your dyno.

  • Page 50: Remove The Dyno Covers

    Remove the twelve screws securing the side cover to the dyno and set aside. Remove the side cover and set aside. top cover side cover Figure 2-21: Removing the Dyno Covers Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-24...

  • Page 51: Drum Module Installation

    (2) P/N 21200038 P/N 63400002 see page 2-42 see page 3-22 toe kick bracket trike carriage adapter P/N 21600012 assembly P/N 71300002 see page 2-45 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-25...
  • Page 52 Remove the crate braces that support the top portion of the crate. Remove the four lag bolts and washers securing the drum to the crate base using a 9/16-inch socket, open or box end wrench. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-26...

  • Page 53: Installing The Ix Drum Module

    10 Continue sliding the drum module towards the dyno until the side panels on the drum module and the dyno are flush. existing screws woodruff key driveline woodruff key iX drum module existing screws Figure 2-22: Installing the Driveline and the Drum Module Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-27...
  • Page 54 15 Replace the existing set screws on the driveline assembly with the thread-lock set screws provided. 16 Tighten the driveline set screws. not visible from this view secure connector plate Figure 2-23: Securing the Drum Module to the Dyno Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-28...

  • Page 55: Installing The Bulkheads

    Secure the middle bulkhead to the dyno frame using five 1/4-20 x 5/8-inch pan- head torx screws. monitor support brace front bulkhead middle bulkhead Figure 2-24: Securing the Front and Middle Bulkheads Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-29...
  • Page 56 • Connect the green/yellow wire to ground Secure the dyno side cover to the bulkheads using the eleven screws removed earlier. toe kick bracket dyno side cover fan socket Figure 2-25: Securing the Dyno Side Cover Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-30...
  • Page 57 10 Secure the drum side cover to the drum module using the eight 1/4-20 x 5/8-inch button-head screws removed earlier. dyno top cover drum side cover Figure 2-26: Securing the Dyno Top Cover and Drum Side Cover Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-31...

  • Page 58: Cable Routing

    CPI to the DynoWare RT J - 76950548 speed pick up/brake cable connects the brake solenoid and speed pick up to DRUM 1 on the back of the DynoWare RT Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-32...
  • Page 59 CAN adapter cable or CAN network cable chain *optional accessory S - 76950807 CAN control cable, adapter, 2' connects the DynoWare RT to the CAN control and CAN dyno user cables Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-33...

  • Page 60: Installing The Dynoware Rt Main Module

    You will need the following part: • 66100016 DynoWare RT Main Module Slide the DynoWare RT main module into the bracket assembly in the dyno. MC154 Figure 2-27: Install the DynoWare RT Main Module Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-34...

  • Page 61: Routing The Cables

    16 Attach remote atmos cable (B) to the DynoWare RT module and stick the atmos module to the side of the dyno. 17 Attach the RPM pickup cable (E) to the front of the DynoWare RT module. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-35...
  • Page 62 Note: If you do not have an eddy current brake and/or AFR assembly, insert the CAN termination plug (V) at the end of your CAN network cable chain. Figure 2-28: CAN Network Cable Configuration Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-36...
  • Page 63 23b Insert the PCV CAN termination plug (U) in the PCV module. Note: If you are not using a PCV, be sure to save the PCV CAN termination  plug (U) for future use. Figure 2-29: Routing the Cables Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-37...

  • Page 64: Routing The Power Carriage And Wheel Clamp Cables

    Route the power carriage cable (H) and wheel clamp cable (G) through the opening in the front of the dyno. route cables through cable pass through cover Figure 2-30: Remove the Cable Pass Through Cover Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-38...
  • Page 65 Secure the cable pass through cover to the dyno with the two screws removed earlier. 3-pin wheel clamp cable, G 2-pin power carriage cable, H Figure 2-31: Routing Wheel Clamp and Power Carriage Cables Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-39...

  • Page 66: Side And Top Covers

    Appendix Secure the eddy current brake side cover to the eddy current brake using the eight 1/4-20 x 5/8-inch screws removed earlier. Figure 2-32: Securing the Eddy Current Brake Side Cover Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-40...
  • Page 67 Secure the center cover to the dyno using the six 1/4-20 x 5/8-inch screws removed earlier. eddy current brake top cover drum top cover dyno center cover Figure 2-33: Securing the Eddy Current Brake, Drum, and Dyno Covers Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-41...

  • Page 68: Installing The Ix Covers

    Secure the drum top cover to the drum module using the six 1/4-20 x 5/8-inch screws removed earlier. Secure the center cover to the bulkheads using six 1/4-20 x 5/8-inch screws. drum top cover center cover Figure 2-34: Securing Drum Top Cover and Center Cover Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-42...
  • Page 69 Place the drum safety cover over the drum. This cover has two pins to keep it in place. Risk of injury. Never run a motorcycle on the dyno without this cover in place. drum safety cover Figure 2-35: Installing the Drum Safety Cover Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-43...

  • Page 70: Fan Arm Mounts

    Refer to step 1 on page 2-49 for more information. fan arm mount under monitor support fan arm mount on right side of dyno Figure 2-36: Installing the Fan Arm Mounts Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-44...

  • Page 71: Trike Carriage Adapter And Carriage Assembly

    Lube the tracks with the included lube or use grease. 5/16 x 1-inch bolts trike carriage adapter assembly 3/8 x 1-inch bolts Figure 2-37: Installing the Trike Carriage Adapter Assembly Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-45...

  • Page 72: Installing The Carriage Assembly

    Remove the four 1/4 x 20-inch button-head screws securing the bearing bracket. Remove the bearing bracket and the carriage screw. carriage screw screw bearing bracket Figure 2-38: Remove the Bearing Bracket and Carriage Screw Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-46...
  • Page 73 Note: If you ordered the power carriage accessory, refer to “Power Carriage” on page 3-24 for installation instructions. carriage trike carriage adapter assembly nut block carriage screw hand crank Figure 2-39: Installing the Carriage Assembly Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-47...
  • Page 74 Note: If you purchased the wheel clamp accessory, refer to “Wheel Clamp” on page 3-27 for installation instructions. tire lock tire stop Figure 2-40: Install the Tire Lock and Tire Stop Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-48...

  • Page 75: Monitor Support And Tray

    Insert the pin on the monitor tray into the upper blower arm. tray washers arms washer monitor support fan arm mount under monitor support Figure 2-41: Installing the Monitor Support and Tray Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-49...

  • Page 76: Control Panel And Cable

    Attach the control panel cable to the Button board. access hole button board control panel cable with cable harness wrap cable tie CP030 Figure 2-43: Attach the Control Panel Cable to the Button Board Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-50...
  • Page 77 10 Using the provided cable clamps and 8-32-inch screws, attach the cable bundle to the arms and the support arm. Adjust the service loops to allow for easy movement of the monitor arms without pulling on the cables. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-51...
  • Page 78 CP023 install control panel spindle if you did not purchase the monitor tray Figure 2-45: Install the Control Panel Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-52...

  • Page 79: Final Adjustments And Tests

    Turn on the main circuit breaker inside the CPI door. Note: Use the main circuit breaker to turn power on and off to the dyno. power plug main circuit breaker Figure 2-46: Turn on the Dyno Power Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-53...

  • Page 80: High Pressure Blower Test

    Press and hold the right hand wheel clamp button then press the left hand button to open the clamp. Refer to “Using the Wheel Clamp” on page 4-6 for more information on using the Control Panel. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-54...

  • Page 81: Zip Tube

    Pull the cable wrap tool through the zip tube along the length of the cables. guide body zip tube cable wrap tool end of cables Figure 2-48: Secure the Cable(s) Into the Zip Tube Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-55...

  • Page 82: Ground Hooks

    Secure each ground hook to the floor using two 3/8-16 x 1-inch hex bolts, two 5/16-inch flat washers, and two 3/8-inch lock washers. Figure 2-49: Ground Hook Placement Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-56...

  • Page 83: Ramp Bracket

    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 2-50: Mark and Drill Ramp Bracket Holes Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-57...
  • Page 84 Remove the four 1/4-inch bolts from the rear of the drum cover. Secure the ramp bracket to the rear drum cover using the bolts you just removed. Figure 2-52: Secure the Bracket to the Drum Cover Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-58...
  • Page 85 Place the ramp on the ramp bracket slipping the bolts on the ramp through the large holes on the ramp bracket. Figure 2-53: Place the Ramp on the Dyno Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 2-59...
  • Page 87 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.

  • Page 88: Main Dyno Power

    Disconnect the power plug to ensure all power has been removed from the dyno before performing certain installation procedures. power plug main circuit breaker Figure 3-1: Main Dyno Power Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 89: Air Brake

    A 127 Figure 3-2: Connect Your Shop Air Supply Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 90: Routing The Air Brake Cables And Air Hose

    You will need to provide an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the dynamometer. Figure 3-3: Route the Air Brake Cables and Air Hose Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 91: Installing The Emergency Stop Sticker

    Remove the four screws on the back of the cover and set aside. Remove the control panel rear cover and set aside. CP029 Figure 3-4: Remove the Control Panel Rear Cover Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 92 Figure 3-5: Removing the Button Board Unscrew the black switch body nut and remove the switch body. Set the nut and switch body aside. switch body switch body nut CP033 Figure 3-6: Removing the Switch Body Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 93 A C C E S S O R I E S Air Brake Place the emergency stop sticker over the dyno shutdown sticker. place emergency stop sticker here CP015 Figure 3-7: Placing the Emergency Stop Sticker Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 94 CP033 Figure 3-8: Replacing the Emergency Stop Button Secure the Button board to the control panel using the four screws removed earlier. button board screw CP032 Figure 3-9: Securing the Button Board Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 95: Air Brake Final Adjustments And Tests

      Refer to “Adjusting the Brake Pad Clearance” on page 3-15 for instructions on adjusting the brake pad clearance. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 96 Refer to Figure 3-2 on page 3-3. Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor. outboard brake pad adjust castle nut remove hairpin cotter Figure 3-11: Loosen the Castle Nut Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-10...
  • Page 97 The spring is located on the drum side of the brake assembly. Note: For clarity, the drum is not shown. nut, washer, and spring bolt nut, washer, and spring bolt Figure 3-12: Remove the Brake Spring Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-11...
  • Page 98 Figure 3-13: Remove the Brake Caliper Stop Remove the hairpin cotter from the bottom clevis pin located on the front of the air brake assembly. bottom clevis pin hairpin cotter Figure 3-14: Remove the Bottom Hairpin Cotter Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-12...
  • Page 99 Figure 3-15: Remove the Bottom Pin and the Top Hairpin Cotter Remove the top clevis pin. top clevis pin Figure 3-16: Remove the Top Clevis Pin Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-13...
  • Page 100 18 Adjust the brake pad clearance. Refer to“Adjusting the Brake Pad Clearance” on page 3-15 for complete instructions. 19 Replace the top and right side covers. 20 Connect your shop air. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-14...
  • Page 101 If the pads touch the rotor during a run, the information provided by the dyno will be inaccurate. brake adjusting shim rotor inboard brake pad brake caliper stop bolts Figure 3-18: Adjust Brake Pad Clearance Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-15...

  • Page 102: Air Fuel Ratio Module

    To ensure accurate readings, pump maintenance should be performed every six months, or sooner, depending on usage. Refer to the Air Fuel Ratio Module Installation and User Guide for more information. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-16...

  • Page 103: Extended Carriage

    The following parts are included in the Trike Extension Carriage Support Brace  Assembly P/N 61300057: leveling mount (2) nut, 3/8-16, nylock (4) P/N 21200157 P/N 36488100 mount  nut, 3/8-16, hex (4) P/N 21200158 P/N DM150-011-004 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-17...
  • Page 104 3/8 x 1-inch hex bolts and two 3/8-16 nylock nuts each. Secure each leveling mount using two 3/8-inch nuts. bolts right bracket extension support brace mount nylock nut hex nut leveling mount KU072 Figure 3-19: Assembling the Extension Support Brace Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-18...
  • Page 105 Use the leveling mounts to make the support brace snug against the floor. Tighten the nuts to secure the leveling mounts. extension support extension support brace KU073 leveling mount Figure 3-20: Installing the Extension Support and Brace Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-19...
  • Page 106 Lube the tracks with the included lube or use grease. 5/16 x 1-inch bolts 3/8 x 1-inch bolts trike carriage adapter assembly extension support 5/16 x 1-inch bolts KU074 Figure 3-21: Installing the Trike Carriage Adapter Assembly Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-20...

  • Page 107: Installing The Extended Carriage Assembly

    1/4-20 x 1/2-inch button-head screws removed earlier. Run the extended carriage assembly through the full range of motion and verify there is no binding. Figure 3-22: Installing the Extended Carriage Assembly Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-21...

  • Page 108: High Pressure Blowers

    Place a 1/8-inch thick poly washer around the pin on the blower. Insert the pin on the blower into the upper blower arm. 10 Plug the power cord from the blower into the power source located on the dyno chassis. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-22...
  • Page 109 The blowers can run at any time once the cord is plugged into a power source. clamp lever aluminum washer upper blower arm fan arm mount plug power cord from new lower blower arm blower into dyno chassis Figure 3-23: Installing the Blowers Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-23...

  • Page 110: Power Carriage

    Loosen the set screw on the hand crank and remove the hand crank. Using a 7/16-inch wrench, remove the two bolts securing the flange bearing. flange bearing bolt hand crank Figure 3-24: Remove the Hand Crank Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-24...

  • Page 111: Installing The Power Carriage

    If the motor mount is already installed, skip this step and continue. Note: The flange bearing must be facing so the grease zerk is accessible (facing down). Note: Dynojet recommends using a 1/4-inch ratchet drive with an extension and a 7/16-inch shallow socket to secure the flange bearing bolts. flange bearing...
  • Page 112 10 Secure the motor assembly cover to the motor mount with four 1/4-20 x 1/2-inch button-head screws removed earlier. wheel clamp cable power carriage cable strain relief motor assembly motor assembly coupler spider cover Figure 3-26: Assemble the Power Carriage Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-26...

  • Page 113: Wheel Clamp

    Remove the six 1/4-20 x 1-inch screws securing the wheel clamp cover. Remove the cover and set the cover and screws aside. cover Figure 3-27: Remove the Wheel Clamp Cover Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-27...
  • Page 114 Secure the wheel clamp to the carriage using four 3/8-16 x 1/2-inch bolts, lock washers and flat washers. wheel clamp WC013 Figure 3-28: Secure the Wheel Clamp to the Carriage Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-28...
  • Page 115 Plug the wheel clamp cable into the connector on the wheel clamp motor. strain relief wheel clamp cable WC014 Figure 3-29: Install Wheel Clamp Strain Relief Replace the wheel clamp cover. cover WC015 Figure 3-30: Replace the Wheel Clamp Cover Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-29...

  • Page 116: Final Adjustments And Tests

    Press and hold the right hand wheel clamp button then press the left hand button to open the clamp. Refer to “Using the Wheel Clamp” on page 4-7 for more information on using the control panel. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 3-30...

  • Page 117: Control Panel Interface Operation

    Interface (CPI). To ensure safety and accuracy in the procedures, perform the procedures as they are described. This chapter is divided into the following categories: • Basic Operation, page 4-3 • Power Distribution Assembly, page 4-9 • Maintenance and Troubleshooting, page 4-10 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 118: Introduction

    E-Stop inputs, and controls the various dyno outputs. The CPI is powered internally from the main power that is provided to the dyno. The power supplied is 240VAC 50 or 60 Hz. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 119: Basic Cpi Operation

    FRONT WHEEL MUST BE SECURED AT ALL NOTICE TIMES. TIE DOWN STRAPS MUST BE Check the AFR Pump airflow USED TO STABILIZE THE MOTORCYCLE. regularly. Figure 4-1: Control Panel Features Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 120: Using The Air Fuel Ratio Air Pump

    Refer to the Air Fuel Ratio Module Installation and User Guide for proper operating and maintenance procedures (P/N 98200062). Failure to follow proper procedures may result in inaccurate data or damage to the equipment. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 121: Using The Emergency Stop/Dyno Shutdown

    CAUTION The blower outlets on the front of the dyno are designed to only work with Dynojet provided blowers. Connecting other electrical loads or other blowers to the outlets on the dyno may damage the dyno and void the warranty.

  • Page 122: Using The Power Carriage

    Press and hold the green starter button until the drum reaches maximum speed. Release the green starter button. Use the momentum of the drum to start the bike. Note: Do not re-engage the starter while the drum is turning. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 123: Using The Status Indicator

    Risk of injury. Be sure the wheel clamp is free and clear of any obstruction. Do not operate the dyno if the wheel clamp indicator light is not on steady. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 124 The status indicator light will be blinking to indicate the wheel is not secured and a dyno run should not be attempted. Continue to open the clamp far enough to allow the next bike to be loaded easily. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 125: Power Distribution Assembly

    These breakers do not provide a manual disconnect. main dyno circuit breaker and disconnect P 232 blower circuit breakers right blower on top Figure 4-2: CPI Circuit Breakers Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 126: Maintenance And Troubleshooting

    Pressing the clamp button again will secure the clamp. • If the E-Stop circuit is open or the Emergency Stop button is pressed, the wheel clamp will not operate. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 4-10...

  • Page 127: Replacing The Eddy Current Brake Driver Fuses

    • 20A, Bussman BAF-20 • Fast Blow, Dynojet P/N 54200014 fuse P 232 Figure 4-3: Eddy Current Brake Driver Fuse Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 4-11...

  • Page 128: Troubleshooting Cpi Fuses

    Fuse F2 protects the power carriage drive circuit. If this fuse is open the power carriage motor will not activate. Replace with a 15A mini auto fuse. P 232 control panel F3, F4 interface board F1, F2 status light Figure 4-4: CPI Fuses Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 4-12...

  • Page 129: Basic Dyno Operation

    HAPTER ASIC PERATION The Dynojet dynamometer gives you the state of the art technology, durability, and accuracy that you need. Dynojet’s advanced engineering delivers the precise horsepower measurements a technician needs to make quick and accurate evaluations of engine performance and drive train problems.

  • Page 130: Loading The Vehicle

    Drive the vehicle onto the dyno and align the vehicle straight with the dyno. Stop the vehicle when the drive axle is centered on the drum. adjust carriage all the way out center drive axle on dyno drum Figure 5-1: Load the Vehicle Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 131 Tighten the four tie-down straps evenly making sure the drive wheels remain centered on the drum. Never perform a dyno run if the tie-down straps are not in place or they are damaged. Figure 5-2: Load the Vehicle—Top View Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 132: Connecting The Rpm Pickup

    Connecting the RPM Pickup CONNECTING THE RPM PICKUP Your Dynojet dynamometer includes a primary wire inductive pickup and a secondary wire inductive pickup. These small “clothespin like” inductive pickups are used to sense RPM. An RPM pickup is required if you want to view torque graphs. Generally you will use one secondary wire inductive pickup on a spark plug wire.

  • Page 133: Connecting The Primary Inductive Pickup

    Note: You must ground the vehicle to the dyno for the electronics to function properly. Refer to “Grounding the Vehicle” on page 5-8. connect primary coil inductive pickup on the negative side of the coil Figure 5-3: Connect the Primary Inductive Pickup Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 134 Refer to “Grounding the Vehicle” on page 5-8. connect secondary coil inductive pickup on the coil wire connect secondary inductive pickup on the coil wires coil Figure 5-4: Connect the Secondary Inductive Pickup Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 135 • Using a jumper wire, ground the metal case of the inductive clip to the motorcycle chassis. Route the inductive wire(s) 90 degrees (perpendicular) away from the motorcycle. When laid alongside (parallel) to the motorcycle they can act as an antenna. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 136: Grounding The Vehicle

    Secure the grounding bracket to this location using one 1/4-20 x 1/2-inch screw. Attach the vehicle ground cable to an exhaust bolt or engine bolt on the vehicle. Attach the vehicle ground cable to the grounding bracket. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 137: Pre-Run Inspection

    Never allow any person(s) to stand behind the dyno or vehicle when it is being operated. Only the operator should be near the dyno or the vehicle during the test. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 138: Before Starting The Engine

    • Fix any fuel, oil, or coolant leaks that may have shown up after engine warm up and check the carburetor for leaks. • Any loud or unusual engine noises or excessive exhaust smoke should be resolved before continuing. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 5-10...

  • Page 139: Using The Starter

    With the bike properly loaded and secured, you are now ready to begin making runs and using your dyno. From here you will need to refer to the Power Core Help for detailed information on using the Power Core suite of applications. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide 5-11...

  • Page 140: Making A Test Run

    CAUTION Using the vehicle’s own brakes to slow or stop the drum at speeds over 30 m.p.h. can severely overheat the brake parts. Dynojet dynamometers with the air brake or eddy current brake accessory can be used to slow the vehicle and drum to a full stop at any speed.

  • Page 141: Preventative Maintenance

    This section contains basic preventative maintenance and troubleshooting information for the wheel clamp and CPI fuses. To maintain proper dynamometer operation, Dynojet recommends you make routine checks of the dyno. • Drum—keep the drum clean and keep all objects clear of the drum.

  • Page 143: Appendix A Red Head Anchor Installation

    Anchor spacing and edge distance requirements (anchor installation locations) are the responsibility of the engineer of record. CONTACT INFORMATION FOR ITW RAMSET/RED HEAD Contact ITW Ramset/Red Head at 1-630-350-0370, or 1300 North Michael Drive,  Wood Dale, IL 60191. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 144 Drill the hole in the concrete the same outside diameter as the anchor being used to any depth exceeding minimum embedment. Figure A-1: Red Head Anchor—Drill the Hole Insert the anchor. anchor Figure A-2: Red Head Anchor—Insert the Anchor Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 145 Note: Use only Ramset/Red Head setting tools to insure proper installation. setting tool Figure A-4: Red Head Anchor—Expand the Anchor Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 147: Appendix B Power Requirements And Installation

    This Appendix is divided into the following categories: • North America, Japan, and Locations Using 60 Hz Power, on page B-2 • Excluding North America and Japan, on page B-5 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 148: Power Requirements And Installation-North America, Japan, And Locations Using 60 Hz Power

    UL and NEC safety standards. Note: If you are installing your dyno in North American or Japan and the dyno is not equipped with twist lock four wire grounded plug, contact Dynojet before attempting to connect the dyno.

  • Page 149: Testing For Correct Voltages

    You must have a licensed electrician correct the power connection. Connecting the dyno to the incorrect voltage can result in damage to the dyno and will void the dyno warranty. Contact Dynojet with any questions. Using a voltmeter that is capable of measuring AC voltage, measure between the points listed below and verify that the correct voltages are present.

  • Page 150: Hard Wiring To The Building

    Refer to the previous table for testing and probe the new connections as follows: • white wire as location #2 • black wire as location #4 • green wire as location #3 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 151: Power Requirements And Installation-Excluding North America And Japan

    Failure to follow these instructions could result in personal injury or damage to the dyno. Connecting the dyno to the incorrect voltage will void the dyno warranty. Contact Dynojet with any questions. The dedicated wall receptacle is a three-pin IEC grounded 30A type and must be wired in accordance with local building codes and requirements.

  • Page 152: Installing The Wall Receptacle

    Connect the grounded 240V conductor to the N terminal. Connect the ungrounded 240V conductor to the L terminal. Connect the ground conductor to the green terminal. L terminal N terminal ground terminal (green) Figure B-2: Wiring the Wall Receptacle Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 153: Testing For Correct Voltages

    Refer to the previous table for testing and probe the new connections as follows: • white wire as location #1 • black wire as location #3 • green wire as location #2 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 155: Appendix C Eec Kit Installation

    This appendix provides instructions for installing the EEC Kit to the model 200iX/250iX motorcycle dyno. This appendix will walk you through installing the EEC finger guards and door safety switch. To ensure safety and accuracy in the procedures, perform the procedures as they are described.

  • Page 156: Removing The Drum Module Hood

    Never operate the dynamometer with the drum module hood removed. CAUTION 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).

  • Page 157: Installing The Eec Finger Guards

    Figure C-2: Secure the EEC Finger Guards—200i/250i and 200iX/250iX Secure the drum module hood with the EEC finger guards to the dyno using the eight screws removed earlier. Secure the iX drum module hood with the EEC finger guards to the dyno using the eight screws removed earlier.

  • Page 158: Adjusting The Eec Finger Guards

    Do not operate the dynamometer without the EEC finger guards properly installed. The gap between the finger guards and the drum must be less than 0.64 centimeters. adjust screw adjust clearance Figure C-3: Adjust the EEC Finger Guard Clearance Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 159: Door Safety Switch

    “Main Dyno Power” on page 3-2. Remove the three screws securing the CPI cover and set aside. Remove the CPI cover and set aside. CPI cover Figure C-4: Remove the CPI Cover Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 160 The air brake should be applied holding the drum and the status light on the control panel will be flashing. 13 Depress the safety switch and the air brake will release and the status light will be on steady. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 161: Appendix D Folding Ramp Installation

    This document provides instructions for installing the model 200i/250i folding ramp assembly (P/N 82944001) and the model iX folding ramp assembly (P/N 82900000) to the Dynojet motorcycle dynamometer (dyno). To ensure safety and accuracy in the procedures, perform the procedures as they are described.

  • Page 162: Ramp Installation-Dyno

    This section will walk you through removing the ramp from the crate and installing the ramp on model 200i and 250i motorcycle dynos. EMOVING THE AMP FROM THE RATE Remove the crate top. crate top Figure D-1: Remove the Crate Top Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 163 Ramp Installation—Dyno Remove the crate braces. crate braces Figure D-2: Remove the Crate Braces Remove the 2x2 brace securing the ramp down. 2x2 brace Figure D-3: Remove the 2x2 Brace Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 164 A P P E N D I X D Ramp Installation—Dyno Fold the ramp up. Remove the front crate panel. Remove the braces. fold ramp up braces front crate panel Figure D-4: Fold Ramp Up and Remove Front Crate Panel Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 165 (not visible from this view) Figure D-5: Remove the Bolts and Washers Securing the Ramp to the Crate Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 166 A P P E N D I X D Ramp Installation—Dyno Remove the ramp by sliding it from the front of the crate. Dynojet recommends using two people to remove the ramp from the crate. Figure D-6: Remove the Ramp from the Crate...

  • Page 167: Installing The Ramp On The Dyno

    Figure D-7: Lower the Ramp Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 168 Remove the four 1/4-inch button-head bolts from the top of the dyno. Remove the two 3/8-inch button-head bolts from the back of the dyno. remove four top bolts remove two back bolts Figure D-8: Remove the Bolts from the Dyno Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 169 Secure the sides of the ramp to the dyno using the two button-head bolts removed earlier. secure with four top bolts secure with two back bolts (only one visible) Figure D-9: Secure the Ramp to the Dyno Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 170: Ramp Installation-Ix Upgrade

    The iX folding ramp (P/N 82900000) allows you to easily and safely load wider vehicles such as ATVs onto the dyno. This section will walk you through removing the ramp from the crate and installing the ramp on model 200iX and 250iX motorcycle dynos.
  • Page 171 Note: If the dyno ramp does not have the holes, drill four 1/4-inch holes. dyno ramp iX ramp ramp panel Figure D-11: Securing the Ramp Panel to the Ramp Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide D-11...
  • Page 172 Note: The ramp cover provides easy access to the air pump filter assembly. 12 Route the air fuel hoses through the large holes in the ramp cover. ramp tie-down ramp cover Figure D-12: Securing the Ramp Tie-Down Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide D-12...
  • Page 173 BOVE ROUND I NSTALLATION The above ground model 250iXW Dynojet dynamometer provides the ultimate in powersports dyno tuning and testing capability. With 73-inch total drum width, and extra drum and sliding carriage, the 250iXW can handle UTV's, ATV's, karts, trikes, and motorcycles.

  • Page 174: Dynamometer Specifications-Above Ground Ixw Dyno

    45.72 cm (18.00 in.) width, iXW upgrade 55.88 cm (22.00 in.) drum outside to drum outside 154.94 cm (61.00 in.) Frame structural steel channel and angle Maximum Speed 322 KPH (200 MPH) Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 175 A B O V E G R O U N D I X W I N S T A L L AT I O N Dynamometer Specifications—Above Ground iXW Dyno Figure E-1: Model 250i Dyno with iXW Upgrade Dimensions Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 176 High Pressure Module Blower Air Brake Option (not shown) Wheel Clamp Option Air Pump Option (not shown) Power Carriage Trike Adapter Assembly Figure E-2: Model 250i Dyno with iXW Upgrade and Accessories Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 177: Above Ground Ixw Upgrade Installation

    (2) P/N 21200202 P/N 61300009P see page 2-44 left cover, iXW iXW drum module P/N 21200205 P/N 62100010 with P/N 21200025, 21200143, 21200203, 21229106, 61100028, 71300004 installed Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 178 P/N 36500009 see list of parts below see page 2-45 screw, 1/4-20 x 5/8",  tie down, kart, 6' (6) pan-head, torx (26) P/N APS-R6 P/N 36561045 set screw (2) P/N 36580404 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 179 Remove the crate braces that support the top portion of the crate. Remove the four lag bolts and washers securing the drum to the crate base using a 9/16-inch socket, open or box end wrench. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 180: Installing The Above Ground Ixw Drum Module

    Insert the woodruff key into the keyway on the iXW drum module shaft. Insert the woodruff key into the keyway on the dyno shaft. Slide the driveline over the key on the drum module shaft. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 181 11 Continue sliding the drum module towards the dyno until the side panels on the drum module and the dyno are flush. woodruff key existing screws driveline woodruff key iXW drum module existing screws Figure E-3: Install the Driveline and the iXW Drum Module Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...
  • Page 182 16 Replace the existing set screws on the driveline assembly with the thread-lock set screws provided. 17 Tighten the driveline set screws. not visible from this view secure connector plate Figure E-4: Install the iXW Drum Module to the Dyno Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-10...

  • Page 183: Installing The Bulkheads

    Secure the middle bulkhead to the dyno frame using five 1/4-20 x 5/8-inch pan- head torx screws. monitor support brace front bulkhead middle bulkhead Figure E-5: Securing the Front and Middle Bulkheads Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-11...
  • Page 184 Secure the dyno side cover to the bulkheads using the eleven screws removed earlier. toe kick bracket dyno side cover fan socket Figure E-6: Securing the Toe Kick Bracket and Dyno Side Cover Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-12...

  • Page 185: Continue Dyno Installation

    Figure E-7: Securing the Dyno Top Cover and Drum Side Cover ONTINUE NSTALLATION Continue the dyno installation with “Cable Routing” on page 2-32. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-13...

  • Page 186: Side And Top Covers-Above Ground Ixw Dyno

    32 and Chapter 3 "Accessories". Secure the eddy current brake side cover to the eddy current brake using the eight 1/4-20 x 5/8-inch screws removed earlier. Figure E-8: Securing the Eddy Current Brake Side Cover Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-14...
  • Page 187 Secure the center cover to the dyno using the six 1/4-20 x 5/8-inch screws removed earlier. eddy current brake top cover drum top cover dyno center cover Figure E-9: Securing the Eddy Current Brake, Drum, and Dyno Covers Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-15...
  • Page 188 Secure the left iXW cover to the bulkheads using four 1/4-20 x 5/8-inch screws. Secure the right iXW cover to the bulkheads using four 1/4-20 x 5/8-inch screws. drum top cover left iXW cover right iXW cover Figure E-10: Securing iXW Covers Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-16...

  • Page 189: Continue Dyno Installation

    Risk of injury. Never run a motorcycle on the dyno without this cover in place. drum safety cover Figure E-11: Installing the Drum Safety Cover ONTINUE NSTALLATION Continue the complete dyno installation with “Fan Arm Mounts” on page 2-44. Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-17...

  • Page 190: Ground Hook Installation-Above Ground Ixw Dyno

    Secure each ground hook to the floor using two 3/8-16 x 1-inch hex bolts, two 5/16-inch flat washers, and two 3/8-inch lock washers. Figure E-12: Ground Hook Placement—iXW Dyno Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide E-18...

  • Page 191: Appendix F Torque Values

    PPENDIX ORQUE ALUES This appendix contains tables for standard and metric torque values. Use these values when specified values are not given in other sections of this manual. Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 192: Standard Bolt Torque Values

    • The following tables include values for plain finish and plated fasteners. • Reduce torque by 10% when engine oil is used as a lubricant. CAUTION The following tables are meant to be used as guidelines for Dynojet product torque values only. Always use caution when torquing fasteners. RADE...
  • Page 193 1382 9/16-18 2055 1542 5/8-11 2543 1907 5/8-18 2880 2160 3/4-10 4509 3382 3/4-16 5036 3777 7/8-9 7277 5457 7/8-14 8017 6013 10908 1232 8181 1-12 11934 1348 8951 1011 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide...

  • Page 194: Metric Bolt Torque Values

    • The following tables include values for plain finish and plated fasteners. • Reduce torque by 10% when engine oil is used as a lubricant. CAUTION The following tables are meant to be used as guidelines for Dynojet product torque values only. Always use caution when torquing fasteners. RADE...

  • Page 195: Index

    2-32 features 4-3–4-4 testing 2-54 installing 2-51 using 4-5 overview 4-2 brake cable 2-32 power carriage 4-4, 4-6 brake pads 3-10, 5-13 routing cables 2-50 brake pressure 5-13 starter 4-4, 4-6 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide Index-i...
  • Page 196 1-9, E-18 exhaust extraction 1-4 installing 2-56 fire suppression 1-4 grounding bracket 5-8 intake air fan 1-4 grounding requirements 1-10, 5-8 noise control 1-4 dyno shutdown 4-4, 4-5 dyno shutdown sticker 3-7 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide Index-ii...
  • Page 197 5-12 warnings A-1 metric torque values remote atmos cable 2-32 grade 10.9 F-4 requirements 1-5–1-10 grade 8.8 F-4 battery 1-5 middle bulkhead 2-29, E-11 chassis specifications 1-5, E-2 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide Index-iii...
  • Page 198 2-54, 3-30 standard torque values troubleshooting 4-10 grade 5 F-2 using 4-7 grade 8 F-3 width 1-5, E-2 starter 5-11 woodruff key 2-27, E-8 using 4-6 status indicator 4-4, 4-7 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide Index-iv...
  • Page 199 I N D E X your dyno room 1-4 equalizer box 1-4 exhaust extraction 1-4 fire suppression 1-4 intake air fan 1-4 noise control 1-4 zip tube 2-55 Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide Index-v...

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