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SECTION 4.4
DIAGNOSTIC TESTS
Page 137
DISCUSSION:
The Cylinder Leak Down Tester checks the sealing
(compression) ability of the engine by measuring air
leakage from the combustion chamber. Compression
loss can present many different symptoms. This test
is designed to detect the section of the engine where
the fault lies before disassembling the engine.
PROCEDURE:
1. Remove a spark plug.
2. Gain access to the flywheel. Remove the valve cover.
3. Rotate the engine crankshaft until the piston reaches top
dead center (TDC). Both valves should be closed.
4. Lock the flywheel at top dead center.
5. Attach cylinder leak down tester adapter to spark plug
hole.
6. Connect an air source of at least 90 psi to the leak
down tester.
7. Adjust the regulated pressure on the gauge to 80 psi.
8. Read the right hand gauge on the tester for cylinder
pressure. 20 percent leakage is normally acceptable.
Use good judgement, and listen for air escaping at the
carburetor, the exhaust, and the crankcase breather.
This will determine where the fault lies.
9. Repeat Steps 1 through 8 on remaining cylinder.
RESULTS:
• Airescapesatthecarburetor–checkintakevalve.
• Air escapes through the exhaust – check exhaust
valve.
• Air escapes through the breather – check piston
rings.
• Airescapes from thecylinder head –the head
gasket should be replaced.
CHECK COMPRESSION:
Lost or reduced engine compression can result in (a)
failure of the engine to start, or (b) rough operation.
One or more of the following will usually cause loss of
compression:
• Blownorleakingcylinderheadgasket
• Improperlyseatedorsticking-valves
• WornPistonringsorcylinder.(Thiswillalsoresultin
high oil consumption)
NOTE: For the single cylinder engine, the minimum
allowable compression pressure for a cold engine
is 60 psi.
NOTE: It is extremely difficult to obtain an accu-
rate compression reading without special equip-
ment. For that reason, compression values are
not published for the V-Twin engine. Testing has
proven that an accurate compression indication
can be obtained using the following method.
PROCEDURE:
1. Remove both spark plugs.
2. Insert a compression gauge into either cylinder.
3. Crank the engine until there is no further increase in
pressure.
4. Record the highest reading obtained.
5. Repeat the procedure for the remaining cylinder and
record the highest reading.
RESULTS:
The difference in pressure between the two cylinders
should not exceed 25 percent. If the difference is
greater than 25 percent, loss of compression in the
lowest reading cylinder is indicated.
Example 1: If the pressure reading of cylinder #1 is
165 psi and of cylinder #2, 160 psi, the difference
is 5 psi. Divide “5” by the highest reading (165) to
obtain the percentage of 3.0 percent.
Example 2: No. 1 cylinder reads 160 psi; No. 2
cylinder reads 100 psi. The difference is 60 psi.
Divide “60” by “160” to obtain “37.5” percent. Loss
of compression in No. 2 cylinder is indicated.
If compression is poor, look for one or more of the fol-
lowing causes:
• Loosecylinderheadbolts
• Failedcylinderheadgasket
• Burnedvalvesorvalveseats
• Insufficientvalveclearance
• Warpedcylinderhead
• Warpedvalvestem
• Wornorbrokenpistonring(s)
• Wornordamagedcylinderbore
• Brokenconnectingrod
• Wornvalveseatsorvalves
• Wornvalveguides
NOTE: Refer to Engine Service manual for further
engine service information.
TEST 73 – CHECK SHUTDOWN WIRE
DISCUSSION:
Circuit board action during shutdown will ground Wire
18. Wire 18 is connected to the Ignition Magneto(s).
The grounded magneto will not be able to produce
spark.
PROCEDURE:
1. On V-twin generators, remove Wire 18 from the stud
located above the oil cooler. On single cylinder gen-
erators, disconnect Wire 18 at the bullet connector. See
Figures 32 or 33.
DC CONTROL
PART 4