OTC 5609 Operating Instructions

5609 Cylinder Leakage Tester Kit
Operating Instructions
1. Allow engine to run until sufficiently warm. Turn off engine.
2. Remove all spark plugs. Remove air cleaner, radiator cap, and crankcase filler cap.
3. Rotate crankshaft until piston in cylinder under test is at top dead center on compression
stroke (valves closed).
4. Install proper adapter on end of test hose. Screw adapter with test hose attached into
spark plug hole.
5. Connect test hose quick-disconnect to cylinder leak tester.
6. Turn pressure regulator knob on cylinder leak tester fully counterclockwise.
7. Connect a source of compressed air to the tester. The test pressure used should
be 10 psi less than the maximum pressure produced by the air source, but not to
exceed 100 psi.
8. Slowly turn pressure regulator knob clockwise until left-hand gauge indicates desired
test pressure. Test pressure must not exceed 100 psi. Right-hand gauge will
indicate the pressure maintained in the cylinder under test. The difference between
the gauge readings indicates the amount of leakage in the cylinder. See chart for gauge
readings compared to the percent leakage.
9. When cylinder test is complete, turn pressure regulator knob fully counter-
clockwise before disconnecting and proceeding to next cylinder.
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
0031-0461 0-100 psi Pressure Gauge
0400-3009 Gauge Boot
0400-3117 Pressure Regulator
0400-0138 Hose Assembly, 24"
0180-1522 Cover Plate
Made in China
Right-Hand Gauge Reading, psi
97 96 95 94 93
87 86 85.5 85 84
73 72 71 70.5 70
3 4 5 6 7
Repair Parts List
Part Number Description
0180-0893 10mm Adapter
0180-1495 12mm Adapter
0180-1496 18mm Adapter
0400-3118 Carry Case
0001-3898 Instruction Label
OTC
1-800-533-6127
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...........................
92 91 90 89 88
83 82 81 80 79
69 68 67.5 67 66
8 9 10 11 12
Defective rings or
worn cylinder walls
Defective exhaust
valve
Defective intake
valve
Leaking head
gasket or crack in
block or head
87 86 85
78 77 76.5
65 64.5 64
13 14 15
0001-000-3898 Rev. D