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Operating Instructions
These instructions should be followed for the proper
operation of the cylinder leakage tester:
1. Allow engine to run until sufficiently warm. Turn off
engine.
2. Remove all spark plugs from engine, plus air cleaner,
radiator cap and crankcase filler cap.
3. Rotate crankshaft until piston of cylinder being tested
is at top dead center on the compression stroke.
4. Install the proper adapter into the spark plug hole.
5. Connect tester quick-disconnect to the adapter.
6. Connect an adequate air source to the tester. Air
sources should be 10 psi greater than the regulated
input pressure shown on the left hand gauge.
7. When using a 100 psi source, adjust left-hand,
regulated gauge to read 90 psi.
8. The relative pressure of the cylinder being tested is
automatically indicated on the right-hand gauge. For
example, using the chart below, with a regulated
pressure of 90 psi, a gauge reading of 81 psi indicates
a 10% cylinder leakage.
Left-Hand
Gauge Reading
100 psi
99
98
90 psi
89
88
75 psi
74
73.5
Percentage of
1
2
Leakage
Part Number
Description
0031-0427
0-100 psi Pressure Gauge
0400-3111
Gauge Boot
0400-3117
Pressure Regulator
0400-0138
Hose Assembly, 24"
0180-1502
Cover Plate
Model 2509 Cylinder Leakage Tester Kit
Right- Hand Gauge Reading, psi
97
96
95
94
87
86
85.5
85
73
72
71
70.5
3
4
5
6
Repair Parts List
Part Number
0180-0893
0180-1495
0180-1496
0400-3118
0001-3472
Due to standard engine clearances and normal wear, no
cylinder should be expected to maintain a perfect no-leak
reading. It is important that all cylinders have a relatively
constant reading. A difference of 5 psi between cylinders is
satisfactory. A difference of 10-15 psi indicates the need for
further investigation.
Test Results
By listening or looking for the following, the cause of low
pressure can be determined:
Air escaping from crankcase breather......
Air escaping from exhaust system...........
Air escaping from carburetor..................
Air bubbles in radiator...........................
93
92
91
90
84
83
82
81
70
69
68
67.5
7
8
9
10
Description
10mm Adapter
12mm Adapter
18mm Adapter
Carry Case
Instruction Label
Defective rings or
worn cylinder walls
Defective exhaust
valve
Defective intake
valve
Leaking head
gasket or crack in
block or head
89
88
87
86
80
79
78
77
67
66
65
64.5
11
12
13
14
0001-000-3472
85
76.5
64
15
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