System Pressure Test

PART NO.

SPECIALTY TOOL

HD-45335

Coolant system pressure tester

The cooling system can be pressure tested to identify a leak and to verify a blown engine gasket.

1. Before troubleshooting cooling system, be sure engine coolant level is at COLD FULL mark on overflow bottle when the motorcycle is on the jiffy stand.

2. Using a cloth over pressure cap, turn cap 1/4 turn counterclockwise (CCW) to safety stop. Let pressure escape. Press down and turn cap to pass over safety stops and remove.

3. See Figure 6-3. Clean and inspect filler neck, upper (1) and lower (5) sealing seats, overflow tube (4), and overflow bottle.

NOTE

Bent filler neck cams and safety stops can cause cap to leak or affect pressure limiting valve. Replace the coolant pipe as required.

4. See Figure 6-5. Turn butterfly valve parallel to boss on COOLANT SYSTEM PRESSURE TESTER (HD-45335) head and turn adapter onto head. Turn butterfly valve perpendicular to seal head to adapter.

NOTE

Wet the upper sealing surfaces before turning adapter onto tester head.

Figure 6-5. System Pressure Test

5. Turn double ended pressure cap onto the end of the adapter and onto filler neck. Rotate to the safety stops.

CAUTION

When performing the coolant system pressure test, never exceed the upper limit rating of the pressure cap. Excessive pressure can rupture cooling pipes, hoses, and radiator.

6. Pump tester until pressure reaches 103 kPa (15 psi).

7. Match movement of needle to system pressure test table. See Table 6-5.

Table 6-5. System Pressure Test

NEEDLE MOVEMENT

LEAK

ACTION

Holds steady for 2 minutes

None

None

Drops slowly

Small

Dye test

Drops quickly

Major

Visual

8. Release pressure in system by turning butterfly pressure valve perpendicular to head. Wait until pressure is released before removing double ended cap from filler neck.

LEAK DETECTION DYE TEST

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

Don't pay hundreds of dollars to find out what is wrong with your car. This book is dedicated to helping the do it yourself home and independent technician understand and use OBD-II technology to diagnose and repair their own vehicles.

Get My Free Ebook


Post a comment