Dynojet 200iPX User manual

©2008 Dynojet Research, Inc. All Rights Reserved.
Model 200iPX/250iPX Upgrade Installation Guide
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual, as well as the software described in it, is
furnished under license and may only be used or copied in accordance with the terms of
such license. This manual is furnished for informational use only, is subject to change
without notice, and should not be construed as a commitment by Dynojet. Dynojet
assumes no responsibility or liability for any error or inaccuracies that may appear in this
manual. Except as permitted by such license, no part of this manual may be reproduced,
stored in a retrieval system, or transmitted, in any form or by any means, electronic,
mechanical, recording, or otherwise, without the prior written permission of Dynojet.
The Dynojet logo is a trademark of Dynojet Research, Inc.
Any trademarks, trade names, service marks, or service names owned or registered by any
other company and used in this guide are the property of their respective companies.
Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA.
Printed in USA.
Part Number: 98200014 Version 01 (03/2008)

Model 200iPX/250iPX Upgrade Installation Guide i
T ABLE OF C ONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Chapter 1 Model 200iPX/250iPX Upgrade
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Confirmation of Compliance Testing and Certification . . . . . . . . . . . . . . . . 1-2
Model 200iPX/250iPX Upgrade Specifications . . . . . . . . . . . . . . . . . . . . .1-3
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Verify the Pit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Dyno Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Disconnecting the Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Removing the Cable Cover, End Cap, and Junction Box Cover . . . . . . . . . .1-8
Removing the Right Side Drum Cover . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Removing the Monitor Tray and Arms . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Disconnecting the Cable Track and Moving the Cables . . . . . . . . . . . . . .1-12
Removing the Monitor Support and Junction Box . . . . . . . . . . . . . . . . . . 1-13
Installing the Monitor Support and the Junction Box on the Left Side . . .1-14
Installing the Junction Box Cover, End Cap, and Cable Cover . . . . . . . . .1-15
Installing the Monitor Arms, Monitor Tray, and Left Blower Assembly . . .1-16
Drum Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Removing the Items from Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Installing the iPX Drum Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
Installing the Right Blower Mount and Blower Assembly . . . . . . . . . . . . .1-21
Pit Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
Ground Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28

Model 200iPX/250iPX Upgrade Installation Guide
TABLE OF CONTENTS
ii
Chapter 2 Basic Dyno Operation
Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . .2-5
Connecting The Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Pre-Run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Appendix A Red Head Anchor Installation
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i

Model 200iPX/250iPX Upgrade Installation Guide iii
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.
Always wear protective clothing, ear protection, and eye protection (goggles, safety glasses) when
using and servicing the dynamometer.
Equipment Power Requirements
The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect
voltage will void the dynamometer warranty. Installation may require a licensed electrician.
Potentially Lethal Voltages
Components attached to and within the dynamometer operate with potentially lethal voltages. To
provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power
source before servicing electrical components or wiring. Disconnect all power cords before servicing
electrical components for the greatest assurance of safety.

Model 200iPX/250iPX Upgrade Installation Guide
WARNINGS
iv
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 are exposed. ESD occurs as a result of a difference of potential between two objects
when the two objects touch. Damage occurs as a result of the energy released when the discharge
(touch) occurs. The difference of potential can accumulate by as simple an action as a user moving
across carpet or a seat. If that person’s energy is discharged directly to the electronics, the electronics
can be damaged.
Precautions
To protect against ESD damage, you must eliminate the difference of potential before the electronics
are handled. Touch the chassis of the dynamometer before touching any of the electronics. By touching
the chassis, you discharge any static shocks to the chassis instead of to the electronics.
If you are holding a circuit board or dynamometer component in your hand when you approach the
machine, touch the chassis of the dynamometer with your hand before installing the circuit board or
component.
When handling a circuit board or component to someone, touch that person with your hand first,
then hand them the component.
Always carry circuit boards in anti-static bags when the boards are exposed (removed from the
dynamometer).
Battery Fire and Explosion Hazards
There is a danger of explosion if the battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Discard used batteries according to the
manufacturer’s instructions.
Automotive Batteries
In operation, batteries generate and release flammable hydrogen gas. They must always be assumed
to contain this gas which, if ignited by burning cigarette, naked flame or spark, may cause battery
explosion with dispersion of casing fragments and corrosive liquid electrolyte. Carefully follow
manufacturer's instructions for installation and service. Keep away all sources of gas ignition and do
not allow metallic articles to simultaneously contact the negative and positive terminals of a battery.
Do not allow the positive and negative terminals to short-circuit. The dynamometer chassis is tied to
the negative side of the battery. Do not short between the positive battery terminal or the starter
connections to the chassis. In addition, make sure metal tools such as screw drivers, wrenches, and
torque wrenches do not come in contact with the negative and positive terminals of the battery. Short
circuiting the terminals of the battery can cause burn injuries, damage to the dynamometer, or trigger
explosions.
Charging
Batteries being charged will generate and release flammable hydrogen gas. Charging space should be
ventilated. Keep battery vent caps in position. Prohibit smoking and avoid creation of flames and sparks
nearby.
Wear protective clothing, eye and face protection, when charging or handling batteries.

WARNINGS
Version 1 Model 200iPX/250iPX Upgrade Installation Guide
v
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.
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.

Model 200iPX/250iPX Upgrade Installation Guide 1-1
CHAPTER
1
M ODEL 200 I PX/250 I PX U PGRADE
Thank you for purchasing the 200iPX/250iPX upgrade for Dynojet’s Model
200iP/250iP Motorcycle Dynamometer. This upgrade will allow you to run a kart, ATV,
or trike on your motorcycle dynamometer. Dynojet’s software and dynamometers will
give you the power to get the maximum performance out of vehicles you evaluate.
Whether you are new to the benefits of a chassis dynamometer or an experienced
performance leader, the repeatability and diagnostic tools of WinPEP 7 software and a
Dynojet dynamometer will give you the professional results you are looking for.
This document provides instructions for installing the 200iPX/250iPX upgrade to
Dynojet’s Model 200iP/250iP Motorcycle Dynamometer (dyno). This document will
walk you through the installation and basic dyno operation. To ensure safety and
accuracy in the procedures, perform the procedures as they are described.
Document Part Number: 98200014
Version 1
Last Updated: 03-18-08
This section is divided into the following categories:
•Introduction,page1-2
• Model 200iPX/250iPX Upgrade Specifications, page 1-3
• Verify the Pit Dimensions, page 1-6
•DynoPreparation,page1-7
• Drum Installation, page 1-17
• Pit Cover Installation, page 1-23
• Ground Hook Installation, page 1-28

Model 200iPX/250iPX Upgrade Installation Guide
CHAPTER 1
Introduction
1-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION
Before installing your 200iPX/250iPX upgrade, please take a moment to read this
guide for installation instructions, dyno features, and other important information.
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.
CONFIRMATION OF COMPLIANCE TESTING AND CERTIFICATION
example of convention description
The Caution icon indicates a potential hazard to the
dynamometer equipment. Follow all procedures
exactly as they are described and use care when
performing all procedures.
The Warning icon indicates potential harm to the
person performing a procedure and/or the
dynamometer equipment.
Dynojet Model 200iP, 200iPX, 250iP, and 250iPX dynamometers have
been tested to NFPA 79:2002 and UL 508(A) standards and pass the
requirements.
Certificate Number: US72080032.01

MODEL 200IPX/250IPX UPGRADE
Model 200iPX/250iPX Upgrade Specifications
Version 1 Model 200iPX/250iPX Upgrade Installation Guide
1-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL 200IPX/250IPX UPGRADE SPECIFICATIONS
The following specifications and requirements will help you set up your dyno area for
the 200iPX/250iPX upgrade.
Refer to the model 200iP/250iP installation guide for specifications and requirements
for the bike dyno.
CHASSIS SPECIFICATIONS
description specifications
Length
dyno with standard carriage allow 304.80 cm (120.00 in.)
dyno with extended carriage allow 355.60 cm (140.00 in.)
iPX drum module 76.20 cm (30.00 in.)
pit covers 137.16 cm (54.00 in.)
Height
from bottom of dyno to top of dyno 45.72 - 46.67 cm (18.00 - 18.38 in)
from top of pit to drum guard 5.40 cm (2.13 in)
from top of pit to top of tire carriage 50.64 cm (16.00 in)
Width
dyno with upgrade 271.42 cm (106.86 in)
pit covers 310.29 cm (122.16 in)
Weight
200iPX/250iPX drum module/crated 136 kg (300 pounds)/363 kg (800 pounds)
Drum
diameter, 200iPX/250iPX upgrade 45.72 cm (18.00 inches)
width, 200iPX/250iPX upgrade 55.88 cm (22.00 inches)
Frame structural steel
Maximum Speed 322 KPH (200 MPH)
Maximum Motorcycle Length (front of
front wheel to center of rear wheel)
standard carriage 213 cm (84.00 inches)
extended carriage 256.54 cm (101.00 inches)
Remote Switches remote software control

Model 200iPX/250iPX Upgrade Installation Guide
CHAPTER 1
Model 200iPX/250iPX Upgrade Specifications
1-4
Figure 1-1: Model 250iPX Dyno Dimensions

MODEL 200IPX/250IPX UPGRADE
Model 200iPX/250iPX Upgrade Specifications
Version 1 Model 200iPX/250iPX Upgrade Installation Guide
1-5
Figure 1-2: Model 250iPX Dyno with Accessories
iPX Drum
Module
Eddy Current
Brake
High Pressure
Blower
Wheel Clamp
Option
Power Carriage
Option
Monitor Support
and Tray
Model 250iP
Dyno Module
Control Panel
Interface
houses all electronics
(not shown)
Air Brake Option
(not shown)
Air Pump Option
(not shown)
Control Panel

Model 200iPX/250iPX Upgrade Installation Guide
CHAPTER 1
Verify the Pit Dimensions
1-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VERIFY THE PIT DIMENSIONS
Before placing the dyno in the pit, take a moment to verify that the dimensions of the
pit are correct.
Refer to the pit dimensions (P/N 98229104) you received from your salesman for
more detailed specifications.
• pit depth: 45.00 cm (18.00 in)
• pit length: 294.64 cm (116.00 in)
• pit width: 121.00 cm (48.00 in)
Figure 1-3: Verify the Pit Dimensions

MODEL 200IPX/250IPX UPGRADE
Dyno Preparation
Version 1 Model 200iPX/250iPX Upgrade Installation Guide
1-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DYNO PREPARATION
Use the following instructions to prepare the dyno for installing the upgrade kit.
If your monitor stand is installed on the right side of the dyno, you will need to use
the following instructions to move it to the left side of the dyno.
DISCONNECTING THE POWER
Use the following steps to connect and disconnect power to the dyno.
Always turn the power off when connecting and disconnecting cables.
1 Use the main breaker to turn power on and off to the dyno.
The main breaker is located inside the CPI door. When the handle is in the down
position all power into the dyno is turned off.
2 Disconnect the power plug to ensure all power has been removed from the dyno
before performing certain installation procedures.
Figure 1-4: Main Dyno Power
PD02
5
main breaker
power plug

Model 200iPX/250iPX Upgrade Installation Guide
CHAPTER 1
Dyno Preparation
1-8
REMOVING THE CABLE COVER, END CAP, AND JUNCTION BOX COVER
If your monitor stand is mounted on the left side of your dyno, skip to “Removing the
Right Side Drum Cover” on page 1-10.
If this is a new dyno installation, skip to “Installing the Monitor Support and the
Junction Box on the Left Side” on page 1-14.
1 Remove the four 8-32 screws securing the cable cover to the end cap and
one 8-32 screw securing the cable cover to the junction box and set aside.
2 Remove the cable cover and set aside.
3 Remove the two 1/4-20 button-head screws securing the end cap to the pit cover
and set aside.
4 Remove the end cap and set aside.
Figure 1-5: Remove the Cable Cover and End Cap
PD042
end cap
cable cover

MODEL 200IPX/250IPX UPGRADE
Dyno Preparation
Version 1 Model 200iPX/250iPX Upgrade Installation Guide
1-9
5 Remove the two 8-32 screws securing the junction box cover and set aside.
6 Remove the junction box cover and set aside.
Figure 1-6: Remove the Junction Box Cover
junction box cover

Model 200iPX/250iPX Upgrade Installation Guide
CHAPTER 1
Dyno Preparation
1-10
REMOVING THE RIGHT SIDE DRUM COVER
1 Remove the four 3/8-16 x 1/2-inch button-head flange screws securing the right
side drum cover to the dyno and set aside.
2 Remove the four 1/4-20 x 1/2-inch button-head flange screws securing the right
side drum cover to the drum guard bracket and set aside.
3 Remove the right side drum cover and discard. This cover will be replaced.
4 Remove the four 3/8-16 x 1/2-inch button-head flange screws securing the middle
drum cover to the dyno and set aside.
Note: You do not need to remove the cover. Removing the screws will allow the
cables to be routed under this cover later.
Figure 1-7: Remove the Right Side Drum Cover
right side drum cover
middle drum cover

MODEL 200IPX/250IPX UPGRADE
Dyno Preparation
Version 1 Model 200iPX/250iPX Upgrade Installation Guide
1-11
REMOVING THE MONITOR TRAY AND ARMS
If your monitor stand is mounted on the left side of your dyno, skip to “Drum
Installation” on page 1-17.
1 Disconnect any cables to the control panel along with any other cables you may
have attached to the monitor arms and monitor tray.
Refer to the model 200iP/250iP installation guide for more information.
2 Remove the monitor tray and set aside.
3 Remove each arm and the washers and set aside.
Figure 1-8: Remove the Monitor Tray and Arms
second arm
poly washer
first arm
monitor tray
support arm
poly washer
poly washer

Model 200iPX/250iPX Upgrade Installation Guide
CHAPTER 1
Dyno Preparation
1-12
DISCONNECTING THE CABLE TRACK AND MOVING THE CABLES
1 Remove the 1/4-20 screw securing the cable track bracket to the wheel clamp and
move the cable track aside. Replace this screw in the wheel clamp.
2 Remove the two 4-40 screws securing the wheel clamp cable track bracket to the
cable track.
3 Flip the wheel clamp cable track bracket over and secure to the cable track using
the two 4-40 screws removed earlier.
4 Remove the two 8-32 screws securing the cable track bracket to the junction box
and set aside.
5 Lift the cable track and the two cables and place on the left side of the tire
carriage.
6 Remove the two screws securing each blower connector to the junction box and
set aside.
7 Pick up the blower connectors and cables and move to the left side of the
carriage.
Note: Be sure to make note which is the left blower connector and which is the
right blower connector.
Figure 1-9: Remove the Cable Track and Blower Connectors
junction box
cable track bracket
wheel clamp
wheel clamp cable
track bracket
blower connectors