Dynojet 200iX User manual

©2010-2016 Dynojet Research, Inc. All Rights Reserved.
Installation Guide For Above Ground Model 200iX and 250iX DynoWare RT Motorcycle
Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual is furnished under license and may only be used
or copied in accordance with the terms of such license. This manual is furnished for
informational use only, is subject to change without notice, and should not be construed
as a commitment by Dynojet. Dynojet assumes no responsibility or liability for any error
or inaccuracies that may appear in this manual. Except as permitted by such license, no
part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, recording, or otherwise, without the prior
written permission of Dynojet.
The Dynojet logo is a trademark of Dynojet Research, Inc.
Any trademarks, trade names, service marks, or service names owned or registered by any
other company and used in this guide are the property of their respective companies.
Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA.
Printed in USA.
Part Number: 98200077 Version 2 (07/2016)
#
RECORD
Dynamometer Number: ____________________________________________________
iX Dynamometer Number: _________________________________________________
iXW Dynamometer Number: _________________________________________________
Eddy Current Brake
(Retarder) Number:_________________________________________________________

i
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
T ABLE OF C ONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Chapter 1 Specifications and Operating Requirements
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Your Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Drill and Drill Bit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Ground Hook Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
DynoWare RT Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Main Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Chapter 2 Installation
Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Routing the Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Installing the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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TABLE OF CONTENTS
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
ii
Secure the Dyno and Brake Module to the Floor . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Remove the Dyno Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
iX Drum Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Removing the Items from Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Installing the iX Drum Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Installing the Bulkheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Identifying the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Installing the DynoWare RT Main Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Routing the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Routing the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . . . . . . . . . 2-38
Side and Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Installing the iX Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Fan Arm Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Trike Carriage Adapter and Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Installing the Trike Carriage Adapter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Installing the Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Monitor Support and Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Control Panel and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
High Pressure Blower Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Trike Carriage Adapter Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Zip Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Ground Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Ramp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Chapter 3 Accessories
Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Routing the Air Brake Cables and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Air Fuel Ratio Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Installing the Extension Support and Trike Carriage Adapter Assembly . . . . . . 3-18
Installing the Extended Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Removing the Hand Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installing the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

TABLE OF CONTENTS
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Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Chapter 4 Control Panel Interface Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Basic CPI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Using the Emergency Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Using the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Understanding Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Using the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Using the Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Using the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Power Distribution Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Main Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
High Pressure Blower Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Maintaining and Troubleshooting the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . 4-10
Replacing the Eddy Current Brake Driver Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Troubleshooting CPI Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Chapter 5 Basic Dyno Operation
Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Connecting The Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Grounding the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Using the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

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TABLE OF CONTENTS
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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Appendix A Red Head Anchor Installation
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix B Power Requirements and Installation
Power Requirements and Installation—North America, Japan,
and Locations Using 60 Hz Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Power Requirements and Installation—Excluding North America and Japan B-5
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Appendix C EEC Kit Installation
EEC Finger Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Removing the Drum Module Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Installing the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Adjusting the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Installing the Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Appendix D Folding Ramp Installation
Ramp Installation—Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Removing the Ramp from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Installing the Ramp on the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Ramp Installation—iX Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Appendix E Above Ground iXW Installation
Dynamometer Specifications—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . E-2
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Above Ground iXW Upgrade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Removing the Items from Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Installing the Above Ground iXW Drum Module . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Installing the Bulkheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
Continue Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
Side and Top Covers—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . . . . . . . E-14
Installing the iXW Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-16
Continue Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-17
Ground Hook Installation—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . . . E-18

TABLE OF CONTENTS
v
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
Appendix F Torque Values
Standard Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Grade 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Grade 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i

vii
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
W 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.
Alwayswearprotectiveclothing,earprotection,andeyeprotection(goggles,safetyglasses)whenusing
and servicing the dynamometer.
CAUTION
Equipment Power Requirements
The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect
voltage will void the dynamometer warranty. Installation may require a licensed electrician.
Potentially Lethal Voltages
Components attached to and within the dynamometer operate with potentially lethal voltages. To
provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power
source before servicing electrical components or wiring. Disconnect all power cords before servicing
electrical components for the greatest assurance of safety.

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
viii
WARNINGS
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 dynamometers
to be very tolerant of static shocks by the users, but the electronics are vulnerable when the electronics
areexposed.ESDoccursasaresultofadifferenceofpotentialbetweentwoobjectswhenthetwoobjects
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
arehandled. Touchthechassisof thedynamometer beforetouchinganyoftheelectronics.Bytouching
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).
CAUTION
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.Keepbatteryventcapsinposition.Prohibitsmokingandavoidcreationofflamesandsparks
nearby.
Wear protective clothing, eye and face protection, when charging or handling batteries.

ix
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
WARNINGS
CAUTION
Grounding Requirements
Always ground the vehicle to the dynamometer. Never operate the dynamometer without properly
grounding the vehicle to the dyno.
Other Potential Hazards
The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for
disconnect before service.
The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.
Any dyno room design must incorporate sufficient exhaust extraction.
Always wear proper ear and eye protection when operating the dynamometer.
Never operate the dynamometer with the covers removed.
Never stand behind the dynamometer when in operation.
Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems
before proceeding.
Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken.
Verify brake operation before beginning any dynamometer testing.
Verify the vehicle is properly secured to the dynamometer.
Verify the vehicle is properly grounded to the dynamometer.
Never operate the blowers without the guards installed.
Exercise care with any dynamometer testing; portions of the dynamometer and vehicle may become
hot.
As with any equipment using electricity and having moving parts, there are potential hazards. To use
this dynamometer safely, the operator should become familiar with the instructions for operation of
the dynamometer and always exercise care when using it.
Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically
recommended in published user-repair instructions that you understand and have the skills to carry
out.

1-1
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
CHAPTER 1
S PECIFICATIONS AND O PERATING
R EQUIREMENTS
Thank you for purchasing Dynojet’s Above Ground Model 200iX/250iX Motorcycle
Dynamometer. Dynojet’s software and dynamometers will give you the power to get
the maximum performance out of vehicles you evaluate. Whether you are new to the
benefits of a chassis dynamometer or an experienced performance leader, the
repeatability and diagnostic tools of Power Core software and a Dynojet dynamometer
will give you the professional results you are looking for.
This document provides instructions for installing the above ground motorcycle
dynamometer (dyno) along with the kart upgrade. This document will walk you
through operating requirements, installation, accessories, and basic dyno operation.
To ensure safety and accuracy in the procedures, perform the procedures as they are
described.
Document Part Number: 98200077
Version 2
Last Updated: 07-25-2016
This chapter is divided into the following categories:
• Introduction, page 1-2
• Dynamometer Specifications and Requirements, page 1-5
• DynoWare RT Electronics, page 1-11

CHAPTER 1
Introduction
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-2
INTRODUCTION
Before installing your dyno, please take a moment to read this guide for installation
instructions, dyno features, and other important information.
This guide is designed to be a reference tool in your everyday work and includes the
following chapters and information:
SPECIFICATIONS AND OPERATING REQUIREMENTS
This chapter describes the requirements and specifications for the dyno.
INSTALLATION
This chapter describes the procedures for installing the dyno.
ACCESSORIES
This chapter lists each dyno accessory alphabetically and describes the procedures for
installing and using the accessory.
CONTROL PANEL INTERFACE OPERATION
This chapter describes the Control Panel Interface (CPI) operating procedures.
BASIC DYNO OPERATION
This chapter describes basic dyno operating procedures.
RED HEAD INSTALLATION
This appendix describes the procedures for installing the Red Head anchors.
POWER REQUIREMENTS
This appendix describes the power requirements and installation instructions for the
dyno.
EEC FINGER GUARD & DOOR SAFETY SWITCH KIT
This appendix describes the procedures for installing the EEC finger guards and door
safety switch.
FOLDING RAMP INSTALLATION
This appendix describes the procedures for installing the folding ramp assemblies for
the dyno and iX upgrade.
ABOVE GROUND IXW INSTALLATION
This appendix describes the procedures for installing the above ground iXW upgrade
kit.
TORQUE VALUES
This appendix describes standard and metric torque values.

1-3
SPECIFICATIONS AND OPERATING REQUIREMENTS
Introduction
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
CONVENTIONS USED INTHIS MANUAL
The conventions used in this manual are designed to protect both the user and the
equipment.
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write
to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, and press releases about our latest
product lines.
example of convention description
CAUTION
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.
#
RECORD
The Record # icon reminds you to record your
dynamometer and/or eddy current brake (retarder)
number on the inside cover of this manual.
Bold Highlights items you can select on in the software
interface, including buttons and menus.

The arrow indicates a menu choice. For example,
“select File
 Open”means “select the File menu,
then select the Open choice on the File menu.”

CHAPTER 1
Introduction
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-4
YOUR DYNO ROOM
This section is not meant to imply that a dyno room is essential to repeatable results
on a Dynojet dynamometer. However, a dyno room with an engine cooling intake fan,
exhaust extraction, and noise reduction capabilities can add a new dimension to your
shop.
A proper dyno room design will help to ensure repeatable, accurate runs. A good dyno
room should do the following:
• minimize noise
• provide a controlled environment for testing
• provide a view window (safety glass) for customers
• be designed with safety in mind
Intake Air Fan—After building your dyno room, you will need to supply an intake air
fan. The intake air fan supplies air to cool the bike’s engine while supplying fresh
oxygen for you and your bike to breathe. It is a common misconception that you
cannot tune a bike without a large fan simulating exact road conditions; however, a
good cooling fan is the only requirement for consistent diagnostics and tuning. The
installed fan should be 5200 CFM.
Equalizer Box—If the air flow rate coming into the dyno room is greater than the air
flow rate leaving the dyno room, the room will become pressurized. A pressurized
dyno room will make measured power misleading. To compensate, you need an
equalizer box. The equalizer box is a baffled (to reduce noise) vent to the outside of
your dyno room. The size of the equalizer box is dependent on the size of your dyno
room and the size of your fans.
Exhaust Extraction—An exhaust fan is needed to remove exhaust gasses, especially
carbon monoxide, from the dyno room. Carbon monoxide is potentially lethal to
people if not removed from the room and will affect engine power when mixed with
fresh air.
Engine exhaust contains poisonous carbon monoxide gas. Breathing it
could cause death. Operate machine in well ventilated area.
Fire Suppression—Always have adequate fire suppression or fire extinguishers in your
dyno room.
Industrial Noise Control, Inc—Industrial Noise Control, Inc. offers a zinc-coated steel
room custom built to your specifications. This room meets all dyno room
requirements. The dyno room must be clean and dry with a comfortable room air
temperature above 32 degrees Fahrenheit (0 degrees Celsius), and have some system
of exhaust extraction. For more information on a dyno room, refer to your 
Pre-Installation Guide For Model 200i, 250i, 200iP, and 250iP Motorcycle
Dynamometers (P/N 98200081).

1-5
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS
The following specifications and requirements will help you set up your dyno area and
verify you have the requirements to operate your dyno safely.
BATTERY REQUIREMENTS
Your 200iX/250iX dyno is designed to carry a group 24 deep-cycle discharge series
battery for operating the starter, power carriage, and optional wheel clamp. The
typical dimensions for this 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 “Battery” on page 2-13.
CHASSIS SPECIFICATIONS
description specifications
Length
with standard carriage allow 271.78 cm (107.00 in.)
with extended carriage allow 322.58 cm (127.00 in.)
with ramp 370.84 cm (146.00 in.)
Height
to top of dyno cover 45.97 cm (18.00 in.)
Width
model 200iX 200.69 cm (79.00 in.)
model 250iX 274.32 cm (108.00 in.)
Weight
model 200i dyno/crated dyno 725 kg (1600 pounds)/771 kg (1700 pounds)
model 250i retarder module/crated 953 kg (2100 pounds)/1,089 kg (2400 pounds)
200iX/250iX drum module/crated 136 kg (300 pounds)/363 kg (800 pounds)
Drum
diameter 45.72 cm (18.00 in.)
width 50.80 cm (20.00 in.)
diameter, 200iX/250iX 45.72 cm (18.00 in.)
width, 200iX/250iX 55.88 cm (22.00 in.)
Frame structural steel
Maximum Speed 322 KPH (200 MPH)
Maximum Motorcycle Length (front of front
wheel to center of rear wheel)
standard carriage 213.00 cm (84.00 in.)
extended carriage 256.54 cm (101.00 in.)
Remote Switches remote software control

CHAPTER 1
Dynamometer Specifications and Requirements
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-6
Figure 1-1: Model 250iX Dyno Dimensions

1-7
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
Figure 1-2: Model 250iX Dyno with Accessories
iX Drum Module
Eddy Current
Brake
High Pressure
Blower
Wheel Clamp
Option
Power Carriage
Option
Monitor Support
and Tray
Model 250i Dyno
Air Brake Option
(not shown)
Air Pump Option
(not shown)
Control Panel
Trike Adapter
Assembly
Folding Ramp Option
(Dyno Module)
Folding Ramp Option
(iX Module)

CHAPTER 1
Dynamometer Specifications and Requirements
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-8
COMPRESSED AIR REQUIREMENTS
You will need to provide an air hose nipple (1/4-inch NPT) to connect your clean, dry
shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the
dynamometer.
The following requirements are needed when the optional air brake is included:
• regulator set to 65 psi max (450 kilopascal)
•airdryer
• shut off valve
• gauge on the regulator
• 1/4-inch NPT pipe thread connector (to attach air to the dyno)
The following requirements are needed for the on-dyno compressed air pump
assembly:
• Clean and dry air, 100 psi or greater, 5 CFM or better flow
• Fittings to hook your air system to a 3/8-inch inside diameter hose (if no air brake
is present)
• 1/4-inch NPT pipe thread compressed air connector
• optional air regulator
COMPUTER SPECIFICATIONS
You will need to provide a computer system to run the Power Core software. Refer to
www.dynojet.com for the latest computer requirements.
description minimum specifications recommended specifications
Operating System Windows 7 or later Windows 7 or later
Processor Dual Core Processor, 
2GHz or faster Intel Core i5 2.8GHz or faster
Memory 4GB System Ram 8GB System Ram or more
Hard Drive 100GB or larger
(54MB required for program) 500GB or larger (54 MB required for program)
Monitor/Graphics Card 1280x1024(SXGA)resolutionor
higher 1600x900 (WSXGA) resolution or higher
Network Adapter 1 free 10/100 Mbps
RJ45 Ethernet Port 1 free 10/100Mbps RJ45 Port on IP 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