©1993-2002 Dynojet Research, Inc. All Rights Reserved. 020329SD Motorcycle Dynamometer Installation Guide Dynojet Research, Inc.
Copyright 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.
TABLE OF CONTENTS List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Chapter 1 Dyno Installation and Setup Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Uncrate the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S ii Motorcycle Dynamometer Installation Guide
LIST OF FIGURES Figure 1-1: Custom Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Figure 1-2: Remove the Ramp Supports and Face . . . . . . . . . . . . . . . . . . . . . 1-5 Figure 1-3: Remove the Tire Carriage from the Crate . . . . . . . . . . . . . . . . . . 1-5 Figure 1-4: Remove the Ramp Bracket from the Crate . . . . . . . . . . . . . . . . . 1-6 Figure 1-5: Hardware Box Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES Figure 3-6: Remove and Replace the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Figure 3-7: Connect Your Shop Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Figure 3-8: Install the Rotor/Taper Lock Assembly . . . . . . . . . . . . . . . . . . . . . 3-6 Figure 3-9: Check for Run Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Figure 3-10: Caliper Assembly Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES Figure 3-35: Install the Nut Block and Front Clamp . . . . . . . . . . . . . . . . . . . 3-27 Figure 3-36: Install the Screw Support Bracket . . . . . . . . . . . . . . . . . . . . . . . 3-28 Figure 3-37: Install the Rotor/Taper Lock Assembly . . . . . . . . . . . . . . . . . . . 3-30 Figure 3-38: Check for Run Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Figure 3-39: Caliper Assembly Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES vi Motorcycle Dynamometer Installation Guide
CHAPTER 1 DYNO INSTALLATION AND SETUP This document provides instructions for installing the Dynojet Motorcycle Dynamometer (dyno). To ensure safety and accuracy in the procedures, perform the procedures as they are described.
CHAPTER 1 Introduction INTRODUCTION ................................... Thank you for purchasing the Dynojet Motorcycle Dynamometer. Before installing your dynamometer (dyno), please take a moment to review the items you will need to provide for your dyno. YOUR DYNO ROOM This section is not meant to imply that a dyno room is essential to repeatable results on a Dynojet dynamometer.
DYNO INSTALLATION AND SETUP Introduction 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. For more information on building a dyno room, read the DynoSource newsletter Volume 1, No. 7 (published by Dynojet) included in your information pack. The dyno room must be clean, dry, at a minimum of 32 degrees Fahrenheit (0 degrees Celsius), and have some system of exhaust extraction.
CHAPTER 1 Introduction CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment. 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.
DYNO INSTALLATION AND SETUP Uncrate the Dyno UNCRATE THE DYNO ................................... Use the following steps to uncrate your dyno. You will need to provide equipment capable of lifting a minimum of 1600 lb. (725 kg.) to move the crated dyno into position in your dyno room. 1 2 Move the crated dyno to a clear area near your dyno room. Remove the three ramp supports and the ramp face. If you ordered your dyno without a ramp, skip to step 3.
CHAPTER 1 Uncrate the Dyno 5 Remove the ramp bracket. The ramp bracket is attached to the bottom of the crate. Figure 1-4: Remove the Ramp Bracket from the Crate 6 Remove the hardware box containing two outrigger bolts and lock washers, the tire carriage screw handle, and the screw support bracket. Refer to Figure 1-5. If you ordered a ramp, the hardware box will also contain six carriage bolts, six flat washers, six lock washers, and six nuts to be used in the ramp installation.
DYNO INSTALLATION AND SETUP Uncrate the Dyno REMOVING THE DYNO FROM THE CRATE You will need to provide equipment capable of lifting a minimum of 1600 lb. (725 kg.) 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 1600 lb. (725 kg.) to attach to the dyno. Dynojet recommends using single loop style straps. 1 2 3 Remove the four bolts securing the hood to the dyno and set aside. Prop up the hood.
CHAPTER 1 Uncrate the Dyno 7 8 Lift the dyno off the crate and move into position in your dyno room. Remove the metal outrigger attached to the bottom of the crate. metal outrigger Figure 1-8: Remove the Metal Outrigger from the Crate 9 Attach the metal outrigger to the dyno. The outrigger is used when strapping the bike to the dyno. 9a Slide the outrigger through the rectangular hold in the dyno frame. 9b Secure the outrigger to the dyno using two 3/8-inch bolts and lockwashers.
DYNO INSTALLATION AND SETUP Tire Carriage TIRE CARRIAGE ................................... The tire carriage is fastened to the bottom of the crate next to the dyno. Refer to step 4 on page 1-5 for instructions on removing the tire carriage from the crate. INSTALLING THE TIRE CARRIAGE 1 Loosen the bolts securing the three carriage clamps and nut block to the top of the dyno using a 1/2-inch socket, open or box end wrench.
CHAPTER 1 Tire Carriage 5 6 7 Using the hand crank, screw the carriage through the nut block. Install the screw support bracket. 6a Place the belleville washers over the end of the carriage screw. It is important the belleville washers are installed in the configuration shown in Figure 1-12. 6b Place the screw support bracket in front of the carriage screw. The two threaded holes in the bracket should face the two matching holes in the carriage. Loosely install the two 1/4 x 1/2-inch button-head screws.
DYNO INSTALLATION AND SETUP Pickup Card PICKUP CARD ................................... The pickup card is an electronic circuit board that accurately senses each drum revolution. INSTALLING THE PICKUP CARD 1 2 Locate the pickup card bracket on the right side of the dyno just ahead of the drum. Install the new pickup card in the notch on the new bracket using two No. 8 screws and lock washers.
CHAPTER 1 Battery BATTERY ................................... A bike starting system is included with your Dynojet Dynamometer. You will need to provide an automotive battery to use this system. The dyno is designed to carry a group 24 series battery with a minimum of 600 cold cranking amps. INSTALLING THE BATTERY 1 2 3 4 5 Locate the red battery cable on the inside of the dyno.
DYNO INSTALLATION AND SETUP Dyno Hood DYNO HOOD ................................... There is a door safety switch included with the European dynos only. European dyno owners will need to install this switch before reinstalling the hood. Installation instructions are included with the switch. INSTALLING THE HOOD 1 2 3 4 Make a final inspection of your dyno and verify that all connections are tight. If you have not already done so, connect the battery.
CHAPTER 1 Ramp Assembly RAMP ASSEMBLY ................................... The ramp is assembled by bolting the ramp face, the ramp supports, and the ramp bracket together. Note: You will need to supply additional wood screws or nails to secure the ramp supports to the ramp face. 1 2 3 Using the ramp bracket as a template, mark and drill six holes in the ramp face using a 3/8-inch bit.
DYNO INSTALLATION AND SETUP Electrical Diagram ELECTRICAL DIAGRAM Figure 1-18: Electrical Diagram Version 3 Motorcycle Dynamometer Installation Guide 1-15
CHAPTER 1 Electrical Diagram 1-16 Motorcycle Dynamometer Installation Guide
CHAPTER 2 HARDWARE INSTALLATION This chapter contains the hardware installation specifications for the DynoWare EX+ modules.
CHAPTER 2 Dynoware EX+ Hardware Stack DYNOWARE EX+ HARDWARE STACK ................................... The standard dynamometer electronics package (hardware stack) is comprised of four interconnected modules: Atmospheric Sensing Module, RPM Module, Dynamometer Input/Output Module, and the CPU Module.
HARDWARE INSTALLATION Dynoware EX+ Hardware Stack RPM MODULE The RPM module receives and processes signals from up to two inductive pickups for measurement of engine RPM. Each input has an automatic gain circuit to compensate for a wide variance of ignition systems. Figure 2-2: RPM Module LED Indicator Description The green LED glows when the RPM module is receiving power. The amber LED flashes when an RPM signal is detected. A steady flash rate, proportional to engine RPM, indicates a good RPM signal.
CHAPTER 2 Dynoware EX+ Hardware Stack DYNAMOMETER INPUT/OUTPUT MODULE The dynamometer input/output module sends and receives data from the dynamometer and the hand-held pendant. The module also contains a buzzer and light which are activated when either the vehicle or the dynamometer speed limit is approached. Figure 2-3: Dynamometer Input/Output Module LED Indicator Description The green LED glows when the dynamometer input/output module is receiving power.
HARDWARE INSTALLATION Dynoware EX+ Hardware Stack CPU MODULE The CPU module contains a 32-bit processor which acquires data from the expansion modules and communicates to the main computer running the WinPEP software. The processor queries the expansion modules to determine their identity and capabilities. Figure 2-4: CPU Module LED Indicator Description The green LED glows when the CPU module is receiving power. The blue LED is lighted when data from the modules is being acquired and saved.
CHAPTER 2 Dynoware EX+ Hardware Stack CONNECTING THE DYNOWARE EX+ CABLES Attach the following cables using the cables that came in the DynoWare package. Refer to Figure 2-5 for cable placement locations. • Attach the 9-pin shielded serial cable to the RS-232 socket on the CPU module and a free COM (serial communications) port on the PC. A 9-pin to 25-pin adapter may be required at the PC. • Attach the 25-pin shielded cable from the dynamometer to the Dynamometer Input/Output module.
CHAPTER 3 OPTIONAL ACCESSORIES This chapter discusses the various optional accessories that are available for the Dynojet Dynamometer (dyno). For more information about these accessories, please contact Dynojet’s Product Specialist’s at 1-800-992-3525 for pricing and availability.
CHAPTER 3 Optional Accessories Overview OPTIONAL ACCESSORIES OVERVIEW ................................... Depending on your current configuration, there are various optional accessories that can be added to your Dynojet Dynamometer to meet your individual needs. All of these options can be added from the factory at the time of original dyno purchase, or purchased separately and added at any time thereafter. A brief description of these accessories follows.
OPTIONAL ACCESSORIES Optional Accessories Overview Power Carriage—The power carriage replaces the standard hand crank with an electrically powered tire carriage allowing you to easily adjust for various wheel base distances with the press of a button. This option is ideal for dynos that are recessed where the hand crank is difficult to access. The power carriage will also reduce the time spent making adjustments for various length motorcycles.
CHAPTER 3 Air Brake AIR BRAKE ................................... The air brake is an electro-pneumatic braking system and includes a two button pendent. The air brake can be utilized to quickly slow the drum after a run is complete. This is especially useful for two-stroke applications when engine compression cannot be used to slow the drum. The air brake can also greatly speed up the testing process.
OPTIONAL ACCESSORIES Air Brake PARTS LIST The following table lists all of the parts included in the Air Brake (P/N 102-201) Installation kit. Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support.
CHAPTER 3 Air Brake INSTALLING THE ROTOR/TAPER LOCK ASSEMBLY When upgrading from a manual brake, the rotor/taper lock assembly and caliper assembly will already be installed. Proceed to “Installing the Air Cylinder and Master Cylinder Assembly” on page 3-8. 1 2 Insert the key into the slot on the shaft. Slide the rotor/taper lock assembly on to the shaft. key shaft rotor/taper lock assembly Figure 3-8: Install the Rotor/Taper Lock Assembly 3 4 Attach the dial indicator to the side of the dyno.
OPTIONAL ACCESSORIES Air Brake INSTALLING THE CALIPER ASSEMBLY 1 2 Tighten the two bolts shown in Figure 3-39. Remove the four bolts and washers in the top and bottom right corners (as shown in Figure 3-10) and set aside. These bolts will be used to mount the caliper assembly in step 3.
CHAPTER 3 Air Brake 4 Adjust the space between the brake pad and the rotor making sure the rotor is able to spin free of contact. Loosen the jam nut and use the adjuster nut to move the brake pads in or out. jam nut adjuster nut Figure 3-12: Adjust the Brake Pad Space INSTALLING THE AIR CYLINDER AND MASTER CYLINDER ASSEMBLY 1 With the air cylinder on the inside of the dyno frame and the mounting plate on the outside, secure the air cylinder with the 1/2-20 x 3/4-inch bolt.
OPTIONAL ACCESSORIES Air Brake 2 Slide the master cylinder assembly through the holes in the air cylinder and through the dyno frame. 3 Secure the master cylinder to the air cylinder with two 1/4 x 4 1/2-inch socket head mounting bolts using a 3/16-inch allen wrench. cut away view of dyno side panel master cylinder bolts air cylinder Figure 3-14: Install the Master Cylinder 4 Run the metal brake line from the master cylinder to the caliper brake hose.
CHAPTER 3 Air Brake INSTALLING THE SPRING BOLT ASSEMBLY 1 2 Push the mounting plate flush with the dyno cabinet. Install the rear retainer, spring, front retainer, and adjuster nut. Be sure the hardware is in this order. Note: You may need to compress the spring to get the adjuster nut on. The distance from the front retainer to the dyno cabinet should be 3.25 inches. Final adjustments will be made later. If the distance is less that 3.
OPTIONAL ACCESSORIES Air Brake INSTALLING THE AIR HOSE 1 2 3 Install the 1-inch grommet into the hole shown in Figure 3-17. Wrap the push lock fitting with thread tape. Refer to Figure 3-18. Insert the five foot section of air hose through the hole. Leave enough air hose exposed and attach it to the regulator.
CHAPTER 3 Air Brake 4 Lift the front of the dyno high enough to access the cut out on the bottom side of the dyno. The dyno is heavy. Use suitable methods to lift and support the dyno while working through these steps. 5 6 7 8 Reach into the access hole in the bottom of the dyno and find the air hose. Place the nut and washer from the bulk head fitting onto the air hose. Insert the air hose through the hole in the front dyno panel and thread the bulk head fitting onto the push lock fitting.
OPTIONAL ACCESSORIES Air Brake WIRING THE AIR VALVE ASSEMBLY The wires that attach to the air valve assembly can be attached in two different places depending on your dyno’s set up. Wire Set Up 1 is generally for older dynos while Wire Set Up 2 is for newer dynos. WIRE SET UP 1 This wire set up is used in older dynos that have an exposed (not in a black box) terminal strip with only eight terminals. If your terminal strip is in a box and has sixteen terminals, refer to Wire Set Up 2 on page 14.
CHAPTER 3 Air Brake WIRE SET UP 2 This wire set up is used in newer dynos where the terminal strip is housed in a black box and has sixteen terminals. If your terminal strip is not in a box and has only eight terminals, refer to Wire Set Up 1 on page 13. 1 2 3 4 Attach the air hose to the coupler and adjust the regulator to 80 psi. Remove the cover from the black box. Run the wires from the air valve through the hole on the side of the black box.
OPTIONAL ACCESSORIES Air Brake FINAL ADJUSTMENTS AND TESTS 1 2 3 4 5 6 7 8 Version 3 Verify the dyno is set up properly, the hardware stack is powered up and operational, and the air supply is connected properly. Verify the brake is off; the red light on the pendant should be off. Fill the master cylinder with DOT 5 brake fluid. Open the bleeder valve on the caliper assembly and use the red brake button on the pendant to activate the brake.
CHAPTER 3 Air Brake AIR BRAKE ASSEMBLY SCHEMATIC Figure 3-23: Air Brake Assembly Schematic 3-16 Motorcycle Dynamometer Installation Guide
OPTIONAL ACCESSORIES Dual Fan DUAL FAN ................................... The dual fan supplies air to cool the bike’s engine. This section will walk you through the fan installation procedures and adjusting the extension arm assembly when a power carriage is installed. The fan extension arm assembly comes ready to mount to the tire carriage on the dyno.
CHAPTER 3 Dual Fan MODIFYING THE TIRE STOP Older dynos may not have the four holes on the tire stop needed to mount the extension arm assembly; you will need to modify the tire stop before continuing with the fan installation instructions. Refer to Figure 3-24 for hole size and placement.
OPTIONAL ACCESSORIES Dual Fan INSTALLING THE EXTENSION ARM ASSEMBLY The fan extension arm assembly comes ready to mount to the tire stop on the dyno. Note: If you have a power carriage installed on your dyno, you will need to make adjustments to the extension arm assembly before mounting the assembly to the dyno. Refer to “Modifying the Extension Arm Assembly (For Power Carriage Only)” on page 3-22. 1 Remove the two screws securing the extension arm assembly to the crate and remove the assembly.
CHAPTER 3 Dual Fan INSTALLING THE FAN ASSEMBLIES Repeat the following steps for each fan assembly. 1 Place a poly washer between the stud and the extension arm. Note: The poly washer is secured to the extension arm with a zip tie. Clip the zip tie before installing the fan assembly. Refer to Figure 3-25. 2 3 Insert the stud on the fan assembly into the extension arm. If not already installed, secure the hand knobs to the extension arm and to the fan base.
OPTIONAL ACCESSORIES Dual Fan INSTALLING THE OUTLET BOX The outlet box mounts to the main bracket on the extension arm assembly. Install the outlet box the same way for dynos with or without a power carriage installed. 1 2 Remove the two button-head screws from the front of the main bracket. Secure the outlet box bracket to the main bracket using the two button-head screws you just removed. Note: Extra button-head screws are included in the hardware bag if needed.
CHAPTER 3 Dual Fan MODIFYING THE EXTENSION ARM ASSEMBLY (FOR POWER CARRIAGE ONLY) When the fan assembly is used with a power carriage, the following modifications must be made to the extension arm assembly before mounting the extension arm assembly to the dyno. Note: These modifications should be made only when a power carriage is installed. 1 2 3 Remove the four hand knobs from the extension arms. Remove arm A, including the poly washer, and set aside.
OPTIONAL ACCESSORIES Dual Fan 4 Flip arm A over, place the poly washer on the stud, and insert into the main bracket from the top. 5 Flip arm B over, place the poly washer on the stud, and insert into arm A from the bottom. Secure Arm B using the bolts, washers, and spacers removed earlier. Note: Arm B is the only arm with a threaded stud. 6 7 Replace the four hand knobs removed earlier.
CHAPTER 3 Extended Carriage EXTENDED CARRIAGE ................................... The extended carriage option increases the maximum wheel base (measured from the front of the front wheel to the center of the rear wheel) from 84 inches to 102 inches for testing raked cruisers and drag bikes. To prevent possible injury, disconnect the battery before performing any dyno maintenance or installing any optional accessory.
OPTIONAL ACCESSORIES Extended Carriage REMOVING THE TIRE CARRIAGE 1 Using a 5/32-inch allen wrench, remove the two button-head screws securing the carriage screw support bracket and remove the bracket. carriage screw support bracket Figure 3-31: Remove the Carriage Screw Support Bracket 2 3 4 Unscrew the carriage until it is free from the nut block. Slide the carriage off the dyno.
CHAPTER 3 Extended Carriage INSTALLING THE EXTENDED CARRIAGE SUPPORT BRACKET 1 Remove the eight screws securing the top cover to the dyno and set aside. Remove the cover and set aside. Removing the cover will make installing the extended carriage support bracket less difficult. cover Figure 3-33: Remove the Top Cover 2 Loosely attach the extended carriage support bracket to the front of the dyno using six 3/8 x 1-inch bolts, twelve 3/8-inch flat washers, and six 3/8-inch nylock nuts.
OPTIONAL ACCESSORIES Extended Carriage 3 Using a straight edge, line the top of the support bracket with the top of the dyno chassis. 4 5 Tighten all six mounting bolts to 30 ft. lb. Install the top cover on the dyno using the eight screws removed earlier. Refer to Figure 3-33. Install the two rear clamps to the dyno cover using the bolts and washers removed earlier. Refer to Figure 3-32.
CHAPTER 3 Extended Carriage INSTALLING THE EXTENDED CARRIAGE 1 2 3 Slide the extended carriage through the nut block and clamps until the carriage screw contacts the nut block. Be sure the slide plate is under the rear carriage clamps. Screw the carriage through the nut block. Install the screw support bracket. 3a Place the belleville washers over the end of the carriage screw. It is important the belleville washers are installed in the configuration shown in Figure 3-36.
OPTIONAL ACCESSORIES Mechanical Brake MECHANICAL BRAKE ................................... The mechanical or manual brake is a foot actuated hydraulic brake. The mechanical brake can be utilized to quickly slow the drum after a run is complete. This is especially useful for two-stroke applications when engine compression cannot be used to slow the drum. The brake can also greatly speed up the testing process.
CHAPTER 3 Mechanical Brake INSTALLING THE ROTOR/TAPER LOCK ASSEMBLY 1 2 3 Remove the hood. Refer to “Removing and Replacing the Hood” on page 3-3. Insert the key into the slot on the shaft. Slide the rotor/taper lock assembly on to the shaft. key shaft rotor/taper lock assembly Figure 3-37: Install the Rotor/Taper Lock Assembly 4 5 Attach the dial indicator to the side of the dyno. Spin the drum and check for run out; the tolerances are +/- .005". Tighten the taper lock bolts.
OPTIONAL ACCESSORIES Mechanical Brake INSTALLING THE CALIPER ASSEMBLY 1 2 Tighten the two bolts shown in Figure 3-39. Remove the four bolts and washers in the top and bottom right corners (as shown in Figure 3-39) and set aside. These bolts will be used to mount the caliper assembly in step 3.
CHAPTER 3 Mechanical Brake 4 Adjust the space between the brake pad and the rotor making sure the rotor is able to spin free of contact. Loosen the jam nut and use the adjuster nut to move the brake pads in or out. jam nut adjuster nut Figure 3-41: Adjust the Brake Pad Space INSTALLING THE MASTER CYLINDER AND FOOT PEDAL 1 2 Position the master cylinder to the inside of the dyno frame and slip the rubber boot on from the outside. The rubber boot slips over the piston sleeve on the master cylinder.
OPTIONAL ACCESSORIES Mechanical Brake 3 4 Remove the plunger from the pedal brake assembly. Slip the plunger into the rubber boot and then reattach it to the pedal brake arm. Run the metal brake line from the master cylinder to the caliper brake hose. 4a Insert a rubber grommet into the hole shown in Figure 3-43. 4b Run the brake line from the master cylinder through the grommet and over to the caliper assembly. 4c Secure the brake line to the master cylinder and to the caliper brake hose.
CHAPTER 3 Monitor Arm MONITOR ARM ................................... This articulated arm and platform supports the monitor, keyboard, and mouse in a convenient position for operation while seated on the motorcycle. The arm can be mounted on either side of the dynamometer. PARTS LIST The following table lists all of the parts included in the Monitor Stand Installation kit. Check your kit against the parts listed to make sure you have received all of the parts.
OPTIONAL ACCESSORIES Monitor Arm INSTALLING THE MONITOR ARM BRACKET 1 2 3 4 Drill a 1/2-inch hole through the aluminum deck plate as shown in Figure 3-44. Use the existing hole under the deck plate as a guide. Fasten the top of the monitor arm bracket to the dyno using a 3/8-inch bolt, 3/8-inch lock washer, and 3/8-inch flat washer. Note: Do not tighten. Secure the bottom of the bracket to the dyno using two 1/2-inch bolts, four 1/2-inch washers, two 1/2-inch lock washers, and two 1/2-inch nuts.
CHAPTER 3 Monitor Arm INSTALLING THE ARMS AND TRAY 1 Place a bushing on the pin of the first arm and insert the arm into the upright. Both arms are identical and interchangeable. 2 3 4 5 Place a bushing on the pin of the second arm and insert the arm into the first arm. Place a bushing on the pin of the tray and insert the tray into the second arm. Insert a plastic cap in both ends of each arm. Check for clearance between the monitor arm and motorcycle, walls, ceiling, etc.
OPTIONAL ACCESSORIES Power Carriage POWER CARRIAGE ................................... The power carriage replaces the standard hand crank with an electrically powered tire carriage allowing you to easily adjust for various wheel base distances with the press of a button. This option is ideal for dynos that are recessed where the hand crank is difficult to access. The power carriage will also reduce the time spent making adjustments for various length motorcycles.
CHAPTER 3 Power Carriage 2 3 4 Using a 5/32-inch allen wrench, loosen the two set screws in the lock collar and remove it from the screw shaft. Using a 7/16-inch wrench, remove the two bolts securing the flange bearing. Pry the flange bearing from the carriage screw shaft with a flat screwdriver and set aside. Note: Clean the shaft with a fine grit emery cloth to remove any remaining thread lock residue. This will make it easier to slide the motor assembly and flange bearing on the shaft.
OPTIONAL ACCESSORIES Power Carriage 2 Slide the motor mount assembly and flange bearing, removed earlier, over the screw shaft. Make sure the flex coupling is on the shaft. Note: The flange bearing must be facing as shown in Figure 3-49 so the grease zerk is accessible. 3 Secure the motor mount assembly and flange bearing to the carriage using two 1/4 x 1-inch bolts and lock washers.
CHAPTER 3 Power Carriage 5 6 Secure the aluminum cover with the two screws you removed earlier. Plug the power cord into a 120 volt power source. Note: For European and 240 volt applications, a step down transformer must be used to provide 120 volts. 7 Using the pendant, move the power carriage through the entire range of motion making sure there is no binding or jamming. Note: When operating the power carriage with a bike on the dyno, make sure the bike is in neutral.
INDEX A air brake 3-2, 3-4–3-15 adjustments and tests 3-15 air cylinder 3-8 air hose 3-11 air valve 3-13 caliper 3-7 master cylinder 3-8 purchased with dyno 3-4, 3-5 rotor/taper lock 3-6 spring bolt 3-10 wire set up 1 3-13 wire set up 2 3-14 air cylinder 3-8 air hose 3-11 air valve 3-13 air vavle wire set up 1 3-13 wire set up 2 3-14 atmospheric sensing module 2-2 B battery 1-12 belleville washers 1-10, 3-28 C caliper air brake 3-7 mechanical brake 3-31 carriage clamps 1-9, 3-25, 3-27 conventions 1-4
INDEX F fan assembly 3-20 fat boy adapter 3-2 G grease zerk 3-39 H hand crank 1-9 hardware stack 2-2 high inertia drum 3-2 hood European door safety switch 1-13 installing 1-13 key switch 1-13 remove, replace 3-3 I Industrial Noise Control, Inc.
T technical support 1-4 tire carriage 1-9–1-10 belleville washers 1-10 carriage clamps 1-9 hand crank 1-9 nut block 1-9 remove from crate 1-5 screw support bracket 1-10 tire stop 3-18 trailer package 3-3 U uncrate the dyno 1-5–1-8 loop straps 1-7 W WinPEP finding manuals on 3-2 system requirements 1-3 Y your dyno room 1-2–1-3 battery 1-3 computer system 1-3 cooling fan 1-2 equalizer box 1-2 exhaust extraction 1-2 noise control 1-3 tie down straps 1-3 Version 3 Motorcycle Dynamometer Installation Gu
