1990 Johnson Evinrude "ES" 9.9 thru 30 Service Manual, P/N 507871, Page 235Get this manual
24Adjust the shift rod as follows : On models with gearcase extension, the extension must be installed before the adjustment can be made Shift the gearcase to the NEUTRAL position Measure from the highest point of the shift rod connector to the top of the gearcase (or extension)This dimension should be between 133 inand 716 in(10,3 mm and 11,0 mm) when the flat surface on the connector faces the driveshaftRotate the shift rod to obtain this dimension
1441 25Pressure and vacuum test the gearcase as follows:
INotel Pressure and vacuum test gearcase before filling Remove the drain plug and gaugein pressure test
Hold down firmly on the driveshaft and pump pressure up to 3-6 psi (21-42 kPa)If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leakage as evidenced by bubbles If the gearcase pressure gauge does not indicate leakage, hold the driveshaft down and increase pressure to 16-18 psi (110-124 kPa)If pressure does not hold, submerge the gearcase in water and check for source of leakageMake necessary repairs and repeat test Screw in vacuum testerPump out to 3-5 in of mercury and see if vacuum holdsThen pump out to 15 inof mercury and checkIf the gearcase fails to hold on either test, put oil around suspected sealIf leak then stops or oil is drawn in, that seal is defectiveWhen the gearcase checks out OK, refill with OMC Hi- Vis gearcase lubricant