1997 Johnson Evinrude "EU" 40 thru 55 2-Cylinder Service Manual, P/N 507265, Page 237Get this manual
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, 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 Install vacuum testerPump out to 3-5 inches (76-127 mm) Hg and see if vacuum holdsThen pump out to 15 inches (381 mm) Hg and checkIfthe gearcase fails to hold on either test, put lubricant around suspected sealIf leak then stops or lubricant is drawn in, that seal is defectiveWhen the gearcase checks out properly, fill the gearcase with the proper lubricant29Fill the gearcase with 20-22 flo oz(600-650 ml) lubricant as follows: Secure gearcase in an upright position Remove the oil level and the oil filldrain plugsReplace the seals if damaged Fill the gearcase with ONIC Ultra-HPF 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 84-86 inIbs(9-10 Nm) Inspect the gearcase oil level after the motor test has been performed30Adjust the shift rod as follows: Check from the shift rod hole to surface of the gearcase using ONIC Universal Shift Rod Height Gauge, PIN 389997, with the shift rod in the NEUTRAL positionRotate the shift rod full turns up or down as necessary to obtain the correct adjustmentCheck the shift rod height with the rod offset to the rearCOA3668