Model 2509 Cylinder Leakage Tester Kit
Operating Instructions
These instructions should be followed for the proper
operation of the cylinder leakage tester:
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.
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.
Test Results
By listening or looking for the following, the cause of low
pressure can be determined:
Air escaping from crankcase breather...… Defective rings or
worn cylinder walls
Air escaping from exhaust system.......…. Defective exhaust
valve
Air escaping from carburetor……………... Defective intake
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.
valve
Air bubbles in radiator………………..……. Leaking head
gasket or crack in
block or head
Left-Hand
Gauge Reading
Right- Hand Gauge Reading, psi
100 psi
99
89
74
98
97
87
73
96
86
72
95
85.5
71
94
85
93
84
70
92
83
69
91
82
68
90
81
89
80
67
88
79
66
87
78
65
86
77
85
76.5
64
90 psi
88
75 psi
73.5
70.5
67.5
64.5
Percentage of
Leakage
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Repair Parts List
Part Number
0031-0427
0400-3111
0400-3117
0400-0138
0180-1502
Description
Part Number
0180-0893
0180-1495
0180-1496
0400-3118
Description
0-100 psi Pressure Gauge
Gauge Boot
10mm Adapter
12mm Adapter
18mm Adapter
Carry Case
Pressure Regulator
Hose Assembly, 24”
0001-000-3472
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0001-3472 Instruction Label
Cover Plate
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