©1993-2002 Dynojet Research, Inc. All Rights Reserved. DynoWare EX+ Upgrade Installation Guide for 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.
TABLE OF CONTENTS List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii DynoWare EX+ Upgrade Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . .
LIST OF FIGURES Figure 1: Components Included In the Upgrade Kit . . . . . . . . . . . . . . . . . . . . 2 Figure 2: DynoWare EX+ Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 3: Remove the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 4: Disconnect the Cables from the Pickup Card . . . . . . . . . . . . . . . . . . 4 Figure 5a: Remove the RPM Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DYNOWARE EX+ UPGRADE This document provides instructions for installing the DynoWare EX+ components. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This manual will walk you through removing the original hardware, installing the DynoWare EX+ components, and making air brake modifications.
DYNOWARE EX+ UPGRADE Parts List PARTS LIST ................................... The following table lists all of the parts included in the DynoWare EX+ Upgrade 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.
INSTALLATION GUIDE Installation INSTALLATION ................................... The DynoWare EX+ system is comprised of four modules: the CPU Module, the Dynamometer Input/Output Module, the RPM Module and the Atmospheric Sensing Module. The upgrade requires a new pickup card and Breakout board (the interface between the dyno and the new DynoWare EX+ hardware). This section will provide you with the information necessary to install and connect the new components.
DYNOWARE EX+ UPGRADE Installation REMOVING THE ORIGINAL HARDWARE 1 Disconnect the cables from the existing pickup card. Figure 4: Disconnect the Cables from the Pickup Card 2 3 4 5 Disconnect the cables from the RPM box, if present. Remove the cable clamps securing the wiring harness under the front dyno cover. Remove the old cables. Be sure to leave the starter cable in place. Remove the RPM box, if present.
INSTALLATION GUIDE Installation INSTALLING THE PICKUP CARD 1 2 3 4 Remove the two 5/8-inch nuts and washers from the bearing case and set aside. Remove the existing pickup card bracket. Install the new pickup card bracket and secure the bracket using the two 5/8-inch washers and nuts removed earlier. Torque the nuts to approximately 150 ft. lb. Note: If you have a high inertia drum, install the extender bracket on your existing pickup card bracket.
DYNOWARE EX+ UPGRADE Installation 6 Align the optical pickup with the tab on the dyno drum axle. Once aligned, tighten the screws to secure the pickup card in place. The optical pickup is very delicate. Be careful not to damage the optical pickup during alignment. pickup tab optical pickup pickup card Figure 8: Optical Pickup Alignment 7 8 Attach the small pickup cable to the Breakout board. The small pickup cable has four wires which connect to the wiring block labeled DRUM 1.
INSTALLATION GUIDE Installation AIR BRAKE MODIFICATIONS If your dyno has an air brake, wiring modifications will need to be made before continuing with the installation. If you do not have an air brake, skip these instructions and continue with “Drilling the Mounting Holes” on page 8. 1 2 3 Locate the wiring block mounted on the cross member just to the front of the drum. Loosen the two screws on the top left of the wiring block. Remove the two wires that go to the air brake solenoid.
DYNOWARE EX+ UPGRADE Installation DRILLING THE MOUNTING HOLES Depending on the age of your dyno, you may need to drill the holes needed to mount the Breakout board. If you dyno already has the required holes, skip these steps and continue with the installation. 1 2 3 4 Locate the Breakout Board Mounting Hole Drill Template found at the end of this manual. Locate the existing holes in the dyno to the right of the pickup card bracket.
INSTALLATION GUIDE Installation INSTALLING THE BREAKOUT BOARD 1 Install the four rubber vibration dampening mounts to the Breakout board using four No. 8 nuts. nuts breakout board dampening mounts Figure 13: Install the Vibration Dampening Mounts 2 Secure the Breakout board cover and board to the dyno using four No. 8 screws. Note: Be sure the large data plug on the Breakout board is facing towards the front of the dyno (away from the drum).
DYNOWARE EX+ UPGRADE Installation 3 Attach the pickup card cable from the Breakout board to the pickup card. 4 Attach the appropriate end of the large PC data cable to the Breakout board and secure with the plug screws (finger tight only). Route the large PC data cable with the starter cable. Secure both cables back under the lip of the front dyno cover using the cable clamps you removed earlier.
INSTALLATION GUIDE Installation WIRING THE DYNOWARE EX+ MODULES 1 2 3 4 Place the DynoWare EX+ modules in a safe location in the shop that is close enough to the computer and the dyno for the cables to reach. Attach the cables to the DynoWare EX+ modules. Refer to Figure 16 for cable placement. • Attach the 9-pin shielded serial cable from the PC to the RS-232 socket on the CPU module. Tighten the screws. • Attach the 25-pin shielded cable from the dynamometer to the Dynamometer Input/Output module.
DYNOWARE EX+ UPGRADE Installation REPLACING THE HOOD 1 2 3 Gently place the hood on the dyno leaving the hood propped up. Reconnect the battery. Secure the hood to the dyno using the four bolts removed earlier.
BREAKOUT BOARD MOUNTING HOLE DRILL TEMPLATE EXISTING HOLES 3.40IN (86.4mm) DRILL 4 HOLES AT 3/16" (5mm) 3.00IN (76.2mm) EXISTING HOLES P:\Templates\ b.o.b.