KONRAD 520 User manual

500 Series
MAINTENANCE MANUAL
NOTICE TO INSTALLER
After completing installation
this Maintenance Manual should be
placed with the Stern Drive for the
Owner’s future use.

All rights reserved. Reproduction or use, without express permission, of editorial or pictorial content,
in any manner, is prohibited. No patent liability is assumed with respect to the use of the information
contained herein. While every precaution has been taken in the preparation of this book, the publisher
assumes no responsibility for errors or omission. Neither is any liability assumed for damages
resulting from use of the information contained herein.
All instructions and diagrams have been checked for accuracy and ease of application; however,
success and safety in working with tools depend to a great extent upon individual accuracy, skill
and caution. For this reason, the publishers are not able to guarantee the result of any procedure
contained herein. Nor can they assume responsibility for any damage to property or injury to persons
occasioned from the procedures. Persons engaging in the procedure do so entirely at their own risk.

Konrad
MODEL 500 Series
STERN DRIVE MAINTENANCE MANUAL
Version 4.1
PART # 10-544
KONRAD, INC.
1421 HANLEY ROAD
HUDSON, WI 54016
715-386-4203
800-927-3545
[email protected]
www.konradmarine.com

TABLE OF CONTENTS
1. Stern Drive
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque Specications for Fasteners . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. General Maintenance
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 5
Specied Lubricant (Gear Oil) . . . . . . . . . . . . . . . . 5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Naval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removing Lubricant . . . . . . . . . . . . . . . . . . . . 7
Checking Lubricant . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Trim/Lift Pump . . . . . . . . . . . . . . . . . . . . . . . 8
Specied Fluids . . . . . . . . . . . . . . . . . . . 8
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering System . . . . . . . . . . . . . . . . . . . . . . . . 9
Specied Fluids . . . . . . . . . . . . . . . . . . . 9
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . 10
520 / 540 Propeller and Hardware . . . . . . . . . . . . . 11
Description and Parts Breakdown . . . . . . . . 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TABLE OF CONTENTS
(continued)
560 Propeller and Hardware . . . . . . . . . . . . . . . . . . 13
Description and Parts Breakdown . . . . . . . . 13
Inspe ction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. Complex Maintenance
Trim/Lift Electrical Drawing (12 Volt) . . . . . . . . . 15
Trim/Lift Electrical Drawing (24 Volt) . . . . . . . . . 16
Trim/Lift Electrical Drawing for Navy RIBs
(24 Volt) . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 17
Setting Trim/Lift Switches . . . . . . . . . . . . . . . . . . . . 18
Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Description and Parts Breakdown . . . . . . . . . 20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . 22
Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Description and Parts Breakdown . . . . . . . . . 24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal & Installation . . . . . . . . . . . . . 24
Trim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Description and Parts Breakdown . . . . . . . . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 26
Trim Cylinder Removal . . . . . . . . . . . . 26
Trim Cylinder Installation . . . . . . . . . . 27
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Description and Parts Breakdown . . . . . . . . . 29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 29
Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Description and Parts Breakdown . . . . . . . . . 30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TABLE OF CONTENTS
(continued)
Continuity Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 32
Description and Parts Breakdown . . . . . . . . . 33
Propeller Shaft Bearing Carrier (Model 520) . . . . . 34
Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rebuilding. . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . 35
Propeller Shaft Seal Carrier (Model 540). . . . . . . . 36
Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rebuilding . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . 37
Propeller Shaft Seal Carrier (Model 560). . . . . . . . 38
Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 39
Rebuilding . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . 40
Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . 41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
30-264 Parts List . . . . . . . . . . . . . . . . . . 42
30-272 Parts List . . . . . . . . . . . . . . . . . . 43
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . 45

500 SERIES MAINTENANCE MANUALMAY 2016 - V4.1 PAGE 1
1. STERN DRIVE
General Information
The Konrad 500 Series stern drives are steerable propulsion systems designed to accommodate
engines that generate up to 738 lb ft of torque. The Konrad 500 Series stern drives have sixteen
degrees (16º) trim range to optimize vessel performance while underway. However, when necessary,
there is an additional thirty degrees (30º) of lift range. The additional lift may only be used when
the stern drive is being serviced or trailered. The Konrad 500 Series stern drives are designed for
applications where the vessel transom angle is thirteen to fourteen degrees (13º to 14º). Applications
that do not meet this criterion may require extra equipment or modications. In some applications, it
may not be possible to use Konrad equipment.
The Konrad 500 Series stern drives are designed to accommodate propellers with three (3) to ve
(5) blades, made of aluminum or stainless steel. Propellers are chosen depending on the application
and performance criterion. The maximum diameter propeller size for the Konrad 520 stern drive
is twenty inches (20”). The maximum diameter propeller for the Konrad 540 and 560 stern drive is
sixteen inches (16”).
Safety Notices
Read and understand all of the safety precautions and warnings before performing any installation
or repair. This list contains the general safety precautions and warnings that MUST be followed to
provide personal safety.
This list is only a suggested safety guideline. Working conditions vary greatly, consequently safety
measures will vary upon your individual circumstances. Always use caution. Make sure the work
area surrounding the product is safe. Be aware of hazardous conditions that can exist.
ALWAYS wear protective eyeglasses and protective footwear when working.
DO NOT wear loose-tting or torn clothing. Remove all jewelry when working.
DO NOT work on anything that is supported ONLY by lifting jacks or a hoist. ALWAYS use blocks
or proper stands to support the product before performing any service work.
TO AVOID PERSONAL INJURY, use a hoist or get assistance when lifting drive components.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of
the correct capacity.
ALWAYS use tools that are in good condition. Make sure you understand how to use them
before doing any service work.
ALWAYS use the same fastener part number (or equivalent) when replacing fasteners. DO NOT
use a fastener of lesser quality if replacements are necessary.
ADDITIONAL SAFETY PRECAUTIONS ARE INCLUDED IN THE PROCEDURES WHENEVER
THEY APPLY.

500 SERIES MAINTENANCE MANUAL MAY 2016 - V4.1
PAGE 2
Operation
The engine produces power (clockwise or counterclockwise rotation) that is transmitted through
a reversing transmission. A coaxial planetary style reversing transmission is normally used in
recreational applications. A twin shaft vertically offset standard reversing transmission (with coaxial
additions available) is normally used in commercial applications. From this point the transmission is
connected via close couple or drive shaft. The power is then transmitted through a series of shafts
and gears and then to the propeller.
Break-In Procedure
NOTE: Make sure the stern drive and the gimbal carrier are properly lled with gear oil prior to
operation.
Any new Konrad stern drive unit, whether a lower, upper or complete, requires a ten (10) hour
break-in running period. Please use the following guidelines during the rst ten (10) hours to assure
optimum performance from your new Konrad stern drive.
1. Avoid full throttle starts.
2. Avoid straining or heavy loading of the stern drive.
3. To achieve even wear patterns on your new drive gear sets, operate at intermittent
throttle levels throughout the entire break-in period.
4. DO NOT exceed seventy-ve percent (75%) of full throttle during the rst ve (5) hours.
5. During the next ve (5) hours of the break-in period, operate periodically at full throttle.
6. The stern drive should be shifted into forward gear a minimum of ten (10) times during
the rst ten (10) hours with moderate (but not excessive) RPM’s after each shift.
7. Change the gear oil when the break-in period is complete. See pages 7 and 8 for oil
change procedure.
NOTE: When the initial oil change is done, small metal particles may be found in the break-in oil. Do
not be alarmed. This is typical during the break-in of the drive and will decrease as you continue to
run the drive system.

500 SERIES MAINTENANCE MANUALMAY 2016 - V4.1 PAGE 3
Torque Specications for Fasteners
Listed below are the torque specications for those fasteners that have a specied torque value.
Securely tighten all other fasteners. Internal drive component torque specications are stated in the
Konrad Technical Manual
(10-591).
Description Torque Value
Drive Shaft Flange to Transmission
Output Flange Shaft Nuts/Bolts (if applicable) 70 lb. ft. (95 Nm)
Transom Assembly / Gimbal Housing
Studs to Inner Transom Plate Nuts (8) 25-30 lb. ft. (34-41 Nm)
Drive Shaft Housing to Gear Housing Nuts and Bolts (8) 35 lb. ft. (47 Nm)
Power Trim Cylinder to Anchor Pin, Nuts (4)
(Rubber Bushings Only)
Tighten until approx.
two (2) threads show.
Power Trim Cylinder to Anchor Pin, Nuts (4)
(Hardened Bushings Only) 30-35 lb ft. (41-47 Nm)
Lifting Bracket Top Cover (and Emergency Tiller Arm
Bracket if applicable) (6) 20 lb. ft. (27 Nm)
Stern Drive Unit to Bell Housing, Nuts (6) 55 lb. ft. (75 Nm)
Gimbal Carrier Bolts (S.H.C.S.) (3) (if applicable) 70 lb. ft. (95 Nm)
520 Propeller Nut (1) 80 lb. ft. (109 Nm)
540 Propeller Nut (1) 55 lb. ft. (75 Nm)
560 Forward Propeller Nut (1) 100 lb.ft. (136 Nm)
560 Aft Propeller Nut (1) 60 ft.lb. (81 Nm)
Removal
1. Rig the Konrad drive for lifting. Secure the stern drive to the lifting device with a nylon strap or
other fastener.
NOTE: An overhead lifting device is the preferred method of lifting the stern drive. The
Konrad 520 weight is 188 lbs (85 kg), the Konrad 540 weight is 153 lbs (69 kg) and
Konrad 560 weight is 167 lbs (75.7 kg).
NOTE: A lifting cart or forklift may be used as an alternate lifting device.
2. Disconnect hydraulic lines from the trim cylinders.
3. Remove the trim cylinders. (Refer to page 29).
4. Remove the six (6) nuts (10-334) and six (6) washers (10-415) attaching the stern drive to the
transom assembly.
5. Remove the continuity cable (10-487) from the upper starboard side transom stud.
6. Slide the stern drive horizontally away from the transom, separating it from
the transom assembly.
NOTE: It is recommended that a new gasket (10-305) be used when drive reinstallation occurs.

500 SERIES MAINTENANCE MANUAL MAY 2016 - V4.1
PAGE 4
Installation
1. Rig the Konrad drive for lifting. Secure the stern drive to the lifting device with a nylon strap or
other fastener.
NOTE: An overhead lifting device is the preferred method of lifting the stern drive. The
Konrad 520 weight is 188 lbs (85 kg), the Konrad 540 weight is 153 lbs (69 kg) and the
Konrad 560 weight is 167 lbs (75.7 kg).
NOTE: A lifting cart or forklift may be used as an alternate lifting device.
2. Grease (using marine grade grease) both sides of the gasket (10-305) and slide it over the six
(6) studs on the bell housing.
3. Grease the bellows (10-230).
4. Grease the splined shaft (10-365).
5. Grease both o-rings (10-306) and (10-493).
6. Grease and insert engagement pin (10-494) into the end of the splined shaft. 3/4 of the
engagement pin should remain visible beyond the end of the splined shaft.
7. Slide the stern drive onto transom assembly. The splined shaft and u-joint assembly must be
held up and guided into the gimbal carrier assembly.
NOTE: It may be necessary to rotate the splined shaft (this can be achieved by sliding
the propeller onto the propeller shaft and rotating it back and forth) or yoke assembly so
the splines line up for the drive to be fully seated against the transom assembly.
NOTE: If this step cannot be achieved, an alternate method is to remove the gimbal
carrier, (from the inside of the vessel) slide the drive onto the transom assembly, then
reinstall the gimbal carrier.
8. Fasten the stern drive to the transom assembly using the six (6) nuts (10-334) and six (6)
washers (10-415). Torque nuts to 55 lb ft (75 Nm).
NOTE: Be sure to put the continuity cable (10-487) on the upper starboard stud before
putting the washer and nut on.

500 SERIES MAINTENANCE MANUALMAY 2016 - V4.1 PAGE 5
2. GENERAL MAINTENANCE
Maintenance Schedule
USE SERVICE HOURS OR TIME INTERVAL, WHICHEVER OCCURS FIRST!!
Location and Service Weekly Every 50
Hours or
60 Days
Every 100
Hours or
120 Days
Every 400
Hours
At Least
Once a
Year
Stern Drive Unit Oil
(Check Level) EVERY DAY
Stern Drive Unit Oil
(Change Break-in Oil) Change the break-in oil after the rst 10 hours
Stern Drive Unit Oil
(Change) EVERY 200 HOURS = Standard Oil
EVERY 400 HOURS = Synthetic Oil
Transom Assembly and Stern
Drive Unit – (Inspect for
corrosion or impact damage,
including propeller)
X X X
Hoses – (Inspect for cracks,
swelling, or other signs
of deterioration. Check
connections for adequate
tightness)
X X
Continuity Circuit – (Check
components for continuity,
loose connections, and broken
or fraying wires)
X X X
Universal Joints (Greaseless)
Replace Every 200 Hours for Heavy Use
Replace Every 1000 Hours for Light Use
Propeller Shaft and Nut
(Lubricate and tighten) X X X
Transom Gimbal Housing
Assembly Swivel Shaft and
Gimbal Bushing
(Inspect for wear)
X X X
Bellows and Bellows Clamps
(Inspect for wear and verify
correct installation) X X
Specied Lubricants (Gear Oil)
NOTE: Synthetic gear lube (75-90W marine certied synthetic gear lube) MUST be used in cold
waters under sixty degrees Fahrenheit, sixteen degrees Celsius
(60°F, 16°C).
General
1. Konrad 75W90 Synthetic Oil Part Number
1 Quart (.95 Liters) (13-090)
2.5 Gallon (9.5 Liters) (13-091)
55 Gallon (208.20 Liters) (13-092)
2. 80w90 Gear Lube Oil

500 SERIES MAINTENANCE MANUAL MAY 2016 - V4.1
PAGE 6
Naval
1. Military PRF 2106, NSN 9150-01-035-5393
Filling
Lubricant Capacity:
Complete Stern Drive, 520 model - approximately seven (7) quarts (6.6 liters).
Complete Stern Drive, 540 model - approximately six (6) quarts (5.7 liters).
Complete Stern Drive, 560 model - approximately six (6) quarts (5.7 liters).
Pour Method:
1. Remove the top cover (10-209) of the stern drive by removing the six (6) socket head cap
screws (10-110). If applicable, remove emergency tiller arm bracket (10-719) by removing
the (4) four socket head cap screws (11-026) and four (4) nylon washers (11-033) and the two
(2) socket head cap screws (10-110) OR If applicable, remove the lifting bracket (12-388) by
removing the two (2) socket head cap screws (12-421), the two (2) nylon washers (11-033) and
the four (4) socket head cap screws (10-110).
2. Pour in gear oil until drive is full.
3. Wait fteen (15) minutes. Rotate the propeller ve or six (5-6) times in both directions during
those fteen (15) minutes.
4. Repeat steps 2 and 3.
5. Replace the top cover (and the emergency tiller arm or lifting bracket if applicable) and torque
to 20 lb ft (27 Nm).
NOTE: Make sure top cover o-ring (10-303) is greased and properly seated.
Pump Method (Pump Required)
1. Remove the upper breather screw (10-010) located on the top of the upper housing, port side
and the lower drain plug (10-155) located on the lower housing.
2. Using a pump, pump gear oil into the drive from the bottom until it comes out of the top
breather plug. Let the gear oil settle for ten to fteen (10 to 15) minutes. Pump additional oil
until it comes out of the top breather plug.
3. Replace lower drain plug and upper breather screw.
NOTE: Both drain plug and breather screw seal/gasket (10-285) must be in place when
reinstalled.

500 SERIES MAINTENANCE MANUALMAY 2016 - V4.1 PAGE 7
Removing Lubricant
1. Trim drive unit to full “Out” or “Up” position.
2. Remove upper drive unit top vent plug (10-010) and bottom ll/drain plug (10-155). Allow
lubricant to drain completely.
NOTE: Discharge of oil or oily waste into or upon the water is a direct violation of
today’s laws. Dispose of or recycle these substances properly.
3. Trim drive unit to full “In” or “Down” position (with anti-ventilation plate level) to complete
draining process (540 and 560 models only).
4. Refer to previous pages for lling procedure and required lubricant.
Checking Lubricant Level
NOTE: The stern drive oil level is checked at the remote oil reservoir. There are two (2) different
styles of reservoirs, only one (1) reservoir is used per drive. The one (1) pint (.47 liter) reservoir
(rectangular bottle) assembly has a part number of 30-179. If you only need a replacement bottle,
that part number is 10-931. The one (1) quart (.95 liter) reservoir (cylindrical bottle) assembly has
a part number of 30-295. If you only need a replacement bottle, that part number is
30-941.
CAUTION: If the lubricant in the reservoir is milky brown or the lubricant is not level with the “ll
line”, there may be a leak in the drive unit. Before further use, the area where the leak occurs
should be identied and corrected. Then rell the unit with new lubricant.
IMPORTANT: Always check oil level when the drive is cool and engine is shut down. Oil level in
the reservoir will rise and fall during drive operation. If the lubricant reservoir is empty, DO NOT
attempt to ll drive unit through reservoir, as air may be trapped in the drive unit and the stern
drive could be damaged from lack of lubrication. After cause for low lubricant has been found and
corrected, rell drive unit with lubricant, as outlined under “Filling” on pages 7 and 8.
30-295
Cylindrical Reservoir Assembly
1 quart (0.95 liters)
30-179
Rectangular Reservoir Assembly
1 Pint (0.47 liters)

500 SERIES MAINTENANCE MANUAL MAY 2016 - V4.1
PAGE 8
Hydraulic Fluids
Trim / Lift Pump
Specied Fluids
General
1. Automatic Transmission Fluid Type Dextron III
2. Light Hydraulic Fluid
Naval
1. Military H-17672, NSN 9150-00-985-7237
2. Military H-5606, NSN 9150-00-223-4134
Fluid Capacity
Trim Pump Reservoir - approximately one (1) quart (.95 liter).
Filling
1. Remove cap (10-689) from the trim/lift pump reservoir.
2. Fill reservoir with specied uid to indication line (maximum level).
IMPORTANT: Check uid level with stern drive unit in the full down position.
Bleeding
1. Fill the trim/lift pump reservoir to appropriate level (if not already done).
2. Remove the down line from trim pump and place it in a container to catch any purged uid.
Hold one (1) nger over the down line port of the trim/lift pump to prevent the intake of air. Trim
the drive all the way up using the toggle switches on the trim/lift control plate.
NOTE: Only the toggle switch that’s LED is illuminated can be used to trim or lift the
drive.
NOTE: Fluid may need to be added if the reservoir bottle level goes below the
minimum.
3. With the drive in the up position, attach the down line to the trim/lift pump.
4. Cycle the drive all the way to the down position and then all the way to the up position. Repeat
this step three or four (3-4) times to purge any remaining air out of the system.

500 SERIES MAINTENANCE MANUALMAY 2016 - V4.1 PAGE 9
Steering System
Specied Fluids
General
1. Automatic Transmission Fluid Type Dextron III
2. Power Steering Fluid
Naval
1. Military H-17672, NSN 9150-00-985-7237
Filling
1. Remove cap from reservalve (depressurize rst), helm pump reservoir, or power steering
pump reservoir.
2. Fill with specied uid to appropriate level.
Emergency Tiller Arm (Navy applications)
Part Number 10-845
.

500 SERIES MAINTENANCE MANUAL MAY 2016 - V4.1
PAGE 10
Bleeding Procedure (NAVY RIBs only)
1. Fill the steering reservalve (30-151) to appropriate level (if not already done).
2. With the bypass valve in the closed position, pressurize the steering system at the
reservalve to 40 psi (276 kPa).
NOTE: Check steering system for leaks.
3. Turn steering bypass valve to the open position. Open the relief valve screws on
reservalve.
4. Oscillate steering wheel slowly forty (40) full rotations clockwise, followed by forty (40)
full rotations counterclockwise. Repeat this procedure for twenty (20) and ten (10) full
rotations.
5. Close bypass valve. Close relief valve screws on reservalve. Oscillate the stern drive
(using the steering wheel) four to ve (4-5) times to the extreme port and starboard
directions.
NOTE: Attempt to move the stern drive manually from left to right (from the outboard
side of the transom). If the movement feels “springy” or “mushy” there is still air in the
system, repeat steps 3 and 4.
6. Fill/top-off the reservalve to the appropriate uid level. Set operating pressure to 25-30 psi
(172-207 kPa).
NOTE: Reservalve gage has a Konrad Marine part number of 11-472.
NOTE: Steering wheel helm pump has a Konrad Marine part number of 30-192.
30-151 Reservalve 30-192 Helm Pump

500 SERIES MAINTENANCE MANUALMAY 2016 - V4.1 PAGE 11
Propeller and Hardware
520 / 540 Description and Parts Breakdown
WARNING: Remote Control must be in NEUTRAL, the engine turned off and ignition key
removed from switch before removing and/or installing propeller.
Model 520 Model 540
When a stainless steel propeller is used, care must be taken to maintain good continuity between the
prop and the prop shaft to prevent corrosion. Periodic removal of the propeller, a thorough cleaning
of its hub, the prop shaft and all mounting components, and lubrication of the shaft with marine
grade grease (or equivalent) will help maintain good continuity and prevent corrosion. A continuity
washer can be installed between the propeller and the splined washer on all models to help maintain
continuity.
Description Qty Part #
A Prop shaft (L) OR 1 10-677
Prop shaft (R) 1 10-596
B Propeller 1 variable
C Prop Hardware Kit 1 10-680
D Propeller Nut 1/0 10-667
A
B
C
D
Description Qty Part #
A Prop shaft (L) OR 1 10-360
Prop shaft (R) 1 10-363
BForward thrust hub 1 10-292
C Propeller 1 variable
D Splined washer 1 10-293
E Tab washer 1 10-295
F Propeller Nut 1 10-296

500 SERIES MAINTENANCE MANUAL MAY 2016 - V4.1
PAGE 12
Inspection
1. Check propeller shaft nut for correct torque – 55 lb ft (75 Nm) 540 model, 80 lb ft (109 Nm) 520
model.
2. Check propeller blades for any indication of damage.
3. Check tab washer - verify at least two (2) tabs are bent over (model
520 only).
Removal
A. Unbend retaining washer tabs using Konrad Tool TO-063 (model 520 only).
B. Place a block of wood between the propeller and cavitation plate.
C. Remove propeller nut.
D. Remove additional propeller hardware (see diagram on previous page).
E. Slide propeller off of splined shaft.
6. Remove thrust washer (model 520 only).
Installation
1. Grease and slide thrust washer onto propeller shaft (model 520 only).
NOTE: Tapered end of thrust washer must be towards the drive.
2. Grease splined area and the threads of the propeller shaft.
3. Place the propeller on the propeller shaft followed by the appropriate hardware (see diagram
on previous page).
4. Torque the propeller nut to 55 lb ft (75 Nm) 540 model, 80 lb ft (109 Nm) 520 model. When
approaching 80 lb ft (109 Nm), 520 model only, make sure that the tabs on the tabbed retaining
washer (at least 2 out of 6) line up with the grooves in the splined washer/hub.
NOTE: A block of wood can be placed between the propeller and the lower drive
housing to prevent the propeller from spinning, while torquing the propeller nut.
5. Bend over the tabs using appropriate tools (model 520 only).

500 SERIES MAINTENANCE MANUALMAY 2016 - V4.1 PAGE 13
560 Description and Parts Breakdown
WARNING: Remote Control must be in NEUTRAL, the engine turned off and ignition key
removed from switch before removing and/or installing propeller.
Model 560
Description Qty Part #
AForward prop shaft 1 12-502
BThrust hub 112-509
CRear propeller 1Variable
DForward prop nut 112-506
ERear prop shaft 112-503
FThrust hub 112-508
GRear propeller 1Variable
HRear prop nut 112-529
When a stainless steel propeller is used, care must be taken to maintain good continuity between the
prop and the prop shaft to prevent corrosion. Periodic removal of the propeller, a thorough cleaning
of its hub, the prop shaft and all mounting components, and lubrication of the shaft with marine
grade grease (or equivalent) will help maintain good continuity and prevent corrosion. A continuity
washer can be installed between the propeller and the splined washer on all models to help maintain
continuity.
Inspection
1. Check Aft propeller shaft nut for correct torque – 60 lb ft (81 Nm).
2. Check propeller blades for any indication of damage.
3. After removal of aft propeller, check forward propeller shaft nut for correct torque – 100 lb ft

500 SERIES MAINTENANCE MANUAL MAY 2016 - V4.1
PAGE 14
(136 Nm).
Removal
1. Once procedure below is completed for the aft propeller, repeat steps to remove the forward
propeller.
2. Place a block of wood between the propeller and cavitation plate.
3. Remove aft propeller nut with 17/16” socket and breaker bar (for forward propeller use hex
wrench TO-121).
4. Remove additional propeller hardware (see diagram on previous page).
5. Slide propellers off of splined shafts.
Installation
1. Slide forward thrust prop onto forward prop shaft so the tapers meet. Some grease can be used
on tapers to hold in place.
2. Grease splined area and the threads of the forward propeller shaft.
3. Place the forward propeller on the propeller shaft until it seats against thrust hub.
4. Torque the forward propeller nut to 100 lb.ft (136 Nm) using hex wrench TO-121.
5. Slide rear thrust prop onto rear prop shaft so the tapers meet. Some grease can be used on
tapers to hold in place.
6. Grease splined area and the threads of the forward propeller shaft.
7. Place the forward propeller on the propeller shaft until it seats against thrust hub.
8. Torque the rear propeller nut to 60 lb.ft (81 Nm) using 17/16” socket wrench.