1990 Johnson Evinrude "ES" 9.9 thru 30 Service Manual, P/N 507871, Page 248Get this manual
1561 35 Pressure and vacuum test the gearcase as follows:
INotel Pressure and vacuum test gearcase before filling Remove the filldrain plug and screw in pressure test gauge Hold down firmly on the driveshaft and pump pressure up to 3-6 psi (21-41 kPa)If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leakage as evidenced by bubblesIf the gearcase pressure does not indicate leakage, 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 the test Screw in vacuum testerPump out 3-5 in(76-127 mm) of mercury and see if vacuum holdsThen pump out 15 in(381 mm) of mercury and checkIf the gearcase fails to hold on either test, put lubrication around suspected sealIf the leak stops or lubricant is drawn in, that seal is defectiveWhen the gearcase checks out properly, fill the gearcase with OMC Hi-Vis gearcase lubricant36Fill the gearcase with 9-11 floz(264-330 ml) lubricant as follows: Secure the gearcase in an upright position Remove the oil level and oil filldrain plugsReplace the seals if damaged Fill the gearcase with OMC Hi-Vis gearcase lube until lubricant appears at the oil level holeInsert the oil level plug firstInstall the filldrain plug Tighten the oil level and filldrain plugs to torque of 60-84 inIbs(7-9 Nm) Inspect the gearcase oil level after the motor test has been performed37 Install water pump assembly as described in Water Pump Servicing, this Section Installation