1996 Johnson Evinrude "ED" 40 thru 55 2-Cylinder Service Manual, P/N 507124, Page 188Get this manual
13Snap cable end onto lever ballSnap cable retainer into anchor block tfi
14Cycle lever from RUN to TILT 10 times before adjusting cableCable AdjustmentDR4604
1The cable must be adjusted so lever and cable will always let valve close completely before lever reaches RUN position2The lever reserve motion is amount of lever movement that remains after valve is closedTo measure lever reserve motionTilt motor upMove lever to positionand then slowly move lever toward RUN POSITION as motor is slowly tilted downValve will first slow tilting movement, then stop movement completelyLeave lever in this CLOSED VALVE POSITION 4To check if valve is completely closed, leave lever in that position and push down hard on gearcaseMotor should hold its position5Hold scale next to end of lever and move lever fromCLOSED VALVE POSITION to RUN POSITION Measure this distance, the lever reserve motion, which should be about 'a in(3 mm)6To adjust, gently pry cable retainer out of anchor block and cable end off lever ball7Turn cable end onto cable (clockwise) to REDUCE the lever reserve motion, and off (counterclockwise) to INCREASE the lever reserve motionEach half turn of the cable end changes the lever reserve motion by about Va in(3 mm)Reconnect cable end to lever ball, and snap cable retainer into anchor block8Remeasure lever reserve motion and readjust until reserve motion is Va in(3 mm)"there is insufficient reserve motion, the valve will leak and the motor will not lock in either up or down positionIf there is excessive reserve motion, the valve will not open enough, and it will be difficult to move the motor9If you run out of threads and cannot remove excess lever reserve motion, cable liner is worn and cable must be replaced