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.