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Author Topic: Put together a SIMPLE air leak down tester for under $30  (Read 1306 times)

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Put together a SIMPLE air leak down tester for under $30
« on: November 26, 2013, 07:29:55 pm »
Put this together to test the rebuild and thought I'd share. Haven't gotten to the point to actually use it but it should be perfect. Will update with results.

Fuel Pump and Vacuum Tester - Harbor Freight - $15
Blood Pressure Monitor (the one with a manual pump) - Amazon - $11
1" PVC Cap for intake - Home Depot - <$1
1.5" Rubber "QWIK CAP" for exhaust flange - Home Depot - <$2


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1991 LT250R
Fresh 67mm Sleeve, FMF Fatty, Boyesen Reeds, PWK39mm
DC Circuit with battery + HID head light, LED tail/stop light and horn
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #1 on: November 26, 2013, 08:47:08 pm »
looks pretty nice
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #2 on: November 27, 2013, 06:14:06 am »
I was just looking at a MityVac yesterday for a new leak down. But now I'm thinking i might save a few dollars and build one. Thanks for the heads up on you set up.
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92 LT250R- Bartlett racing prototype big bore. Wide, Low,  and studded

91 LT250R Mickey Thompson stadium racer

87 LT500R- Mostly stock

89 LT500R IceZilla, mods TBA

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #3 on: November 27, 2013, 07:22:55 am »
I have about 33 $ in the one I built. Works well and really happy with it.
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91 Lt250r Bartlett port and head mod v force 2 Hinson Clutch Basket Cool Head Scp Pipe and silencer ,KN air filter ,EBC clutch, Ohlins  Triple rate Shocks Redone by PEP Shocks,Stock Rear Shock Redone By Pep Shock,  DG nerf Bars , Lonestar axle 2+2,Lonestar Swingarm ,Douglas Red Label rims.

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #4 on: December 06, 2013, 01:34:20 am »
Reporting back, the tester worked great. Found a couple of leaks and took care of them.

There is a single bolt on the side of the case that leads into the crank case. It doesn't hold anything, it just plugs the hole... Anyone know what it's for??
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1991 LT250R
Fresh 67mm Sleeve, FMF Fatty, Boyesen Reeds, PWK39mm
DC Circuit with battery + HID head light, LED tail/stop light and horn
Crappy Plastics

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #5 on: December 06, 2013, 04:53:58 am »
A picture is worth a thousand words!!
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #6 on: December 06, 2013, 05:43:31 am »
This guy...

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1991 LT250R
Fresh 67mm Sleeve, FMF Fatty, Boyesen Reeds, PWK39mm
DC Circuit with battery + HID head light, LED tail/stop light and horn
Crappy Plastics

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #7 on: December 06, 2013, 06:51:00 am »
Thats where you drain the power valve chamber of oil and fuel build up.
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92 LT250R- Bartlett racing prototype big bore. Wide, Low,  and studded

91 LT250R Mickey Thompson stadium racer

87 LT500R- Mostly stock

89 LT500R IceZilla, mods TBA

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #8 on: December 06, 2013, 08:41:29 am »
How often do you guys let that drain out?
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #9 on: December 06, 2013, 09:25:48 am »
I only drain mine when I run outta oil for premix  :))
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92 LT250R- Bartlett racing prototype big bore. Wide, Low,  and studded

91 LT250R Mickey Thompson stadium racer

87 LT500R- Mostly stock

89 LT500R IceZilla, mods TBA

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #10 on: December 06, 2013, 09:27:36 am »
Actually there shouldnt be much oil/ fuel mix in there. If there is, Your motor might be over fueled or a clutch side seal issue.... Im sure there's more to it if thats the case.
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92 LT250R- Bartlett racing prototype big bore. Wide, Low,  and studded

91 LT250R Mickey Thompson stadium racer

87 LT500R- Mostly stock

89 LT500R IceZilla, mods TBA

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #11 on: December 06, 2013, 11:45:58 pm »
Interesting, good to know.
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1991 LT250R
Fresh 67mm Sleeve, FMF Fatty, Boyesen Reeds, PWK39mm
DC Circuit with battery + HID head light, LED tail/stop light and horn
Crappy Plastics

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #12 on: December 13, 2013, 03:58:15 pm »
So I am getting the pieces together to make my own tester. I had the vacuum/pressure gauge in the tool box, the amazon blood pressure gauge with pump is $9.89 with free shipping so it is on the way here.  I am looking at the fittings, did you just pick up a brass T and a fitting that will thread into the spark plug hole? Do you know what size that is off hand? I appreciate your insight to post this.  It will be a very useful tool as I am pretty sure I have a leak in my '87 zilla , am currently putting my '91 lt250r back together, and needing one to chase the demons on a 2003 lt50! Thanks again.
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #13 on: December 13, 2013, 04:11:38 pm »
i am gonna go to lowes this weekend and try to see how cheap, but not so cheap its junk. i can make them for.
i got a nice one now thats built from copper pipe, but i might try to build a few and sale them for the shipping cost. or maybe build a few to
loan out, you pay the shipping both ways and you can use it anytime you want. i might even be able to pay
shipping to you, well wifes work will pay for it. lol  but just as long as i get it back in a week or 2. could save guys
 a few bucks that just dont have the time or cash to spend on something they really dont need. but even tho you
own a 2 stroke you really do need one.
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #14 on: December 13, 2013, 04:32:01 pm »
I will buy one from ya John!
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #15 on: December 13, 2013, 05:34:16 pm »
do you want a copper pipe one or pvc, i guess that will be the 2 you have to chose from.
guess i will price both of them out, i looked on line tho and did not see any low psi gauges at lowes.
i was looking for 0-15 lbs.
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life's journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sidays totally worn out shouting "HOLY SH*T...WHAT A RIDE!"

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #16 on: December 14, 2013, 02:36:15 am »
Rem, I bot a set of plastic T's from autozone, and the brass fitting for the spark plug hole came with the pressure tester kit. I will check the thread and diameter sizes when I get home and post them on here, pretty sure you can find it cheap on ebay.

Grk, I got my gauge from Harbor Freight and it's 0-10psi. If you don't have it in your area you could order it online, but I'm not sure how much they charge for shipping.
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1991 LT250R
Fresh 67mm Sleeve, FMF Fatty, Boyesen Reeds, PWK39mm
DC Circuit with battery + HID head light, LED tail/stop light and horn
Crappy Plastics

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #17 on: December 14, 2013, 08:50:12 am »
That would be great! I appreciate it.
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #18 on: December 14, 2013, 08:53:50 am »
how much was gauge up there, i got one about 45 min away, i am gonna go go up there today, i need to get some tire spoons from there.
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life's journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sidays totally worn out shouting "HOLY SH*T...WHAT A RIDE!"

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #19 on: December 14, 2013, 11:38:30 am »
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1991 LT250R
Fresh 67mm Sleeve, FMF Fatty, Boyesen Reeds, PWK39mm
DC Circuit with battery + HID head light, LED tail/stop light and horn
Crappy Plastics

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #20 on: December 14, 2013, 04:10:14 pm »
man i had no luck today, harbor freight employees suck, they dont know anything... i went to home lowes to, and pep boys.
only parts i got was the plugs, i am gonna try and go to a industrial plumbing store monday, making it out of copper pipe.


plugs were under 4 bucks. lowes had a pretty nice one.
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life's journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sidays totally worn out shouting "HOLY SH*T...WHAT A RIDE!"

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #21 on: December 14, 2013, 05:46:48 pm »
I'd be down for to buy a copper one from you,,, but i would need a different exhaust cap since my pipe has a solid flange
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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #22 on: December 15, 2013, 01:56:59 pm »
Just get rubber freeze plugs.
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91 Lt250r Bartlett port and head mod v force 2 Hinson Clutch Basket Cool Head Scp Pipe and silencer ,KN air filter ,EBC clutch, Ohlins  Triple rate Shocks Redone by PEP Shocks,Stock Rear Shock Redone By Pep Shock,  DG nerf Bars , Lonestar axle 2+2,Lonestar Swingarm ,Douglas Red Label rims.

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #23 on: December 15, 2013, 04:45:32 pm »
i am only going to make the leak tester, you will need to find the plugs to seal your motor.
i am going to hit the plumbing store tomorrow.
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life's journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sidays totally worn out shouting "HOLY SH*T...WHAT A RIDE!"

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Re: Put together a SIMPLE air leak down tester for under $30
« Reply #24 on: December 15, 2013, 06:35:19 pm »
ok i got the gauges and the reducer, now i need help.

i need a 3/4'' female sleeve with threads on the inside at 1/4''
then i can soder the sleeve in it and thread the psi gauge in that.
any idea what that part is called. guess it would be just like heli coil
but i am sure there is a name for it. i just dont know the name. so i need help.
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life's journey is not to arrive at the grave safely in a well preserved body, but rather to skid in sidays totally worn out shouting "HOLY SH*T...WHAT A RIDE!"
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