1992 Johnson Evinrude "EN" 9.9 thru 30 Service Manual, P/N 508142, Page 246Get 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 1332 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 the dimension' 144125Pressure and vacuum test the gearcase as follows:
INotel Pressure and vacuum test gearcase before filling Remove the oil level plug and screw in pressure test gauge 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 bubblesIf 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 inof 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 lubricant145126Fill the gearcase with 8-9 floz(230-260 ml) lubricant as follows: Secure the gearcase in an upright position Remove the oil level and the oil filedrain plugsReplace the seals Fill the gearcase with OMC Hi-Vis gearcase lube until lubricant appears at the oil level holeInsert the oil level plug firstInstall the filldrain plugTighten the oil level and the filldrain plugs to torque of 60-84 inIbs(7-9 Nm) Inspect the gearcase oil level after motor test has been performed27Inspect water pump as described in Water Pump Servicing, this Section6-2.1