Download - MODELS 500 Series · Trim cylinders with anchor pins 26 lbs 11.8 kg Trim pump 13 lbs 5.9 kg Upper housing assembly 100 lbs 45.4 kg Lower housing assembly 67 lbs 30.4 kg Transom assembly

500 Series Technical Manual - i - October 2009

Konrad

MODELS

500 Series

STERN DRIVE TECHNICAL MANUAL

Part #10-591

Konrad, Inc. 1421 Hanley Road

Hudson, WI 54016 USA 715-386-4203

fax 715-386-4219

500 Series Technical Manual - ii - October 2009

500 Series Technical Manual

EDITION 5

All rights reserved. Reproduction or use, without the express consent of Konrad, Inc. of content in any manner is prohibited. All material in this manual at the time of publication is assumed to be free of omissions or errors. However while every precaution has been taken in the preparation of this mannual, it is possible that errors or incorrect material may have been included. In the effort of continuing product improvement, changes in product design and appearance may be made since the time of this publication. Publication of this manual is intended as a service guide for the 500 Series stern drives and is not in any form a binding contract to liability for damage or injuries caused by improper procedure, errors or omissions. All service done to the product using this manual is done solely at the risk of the consumer or service personnel. Publication of the service manual does not imply approvals from Konrad, Inc. for any warranty or liability work to be done by anyone not authorized by Konrad, Inc. All diagrams, procedures and instructions have been reviewed for accuracy and methods of application. Safe practices and success for service of the product described herein, is contributed to the individual’s skill, accuracy and caution. Konrad, Inc. assumes no responsibility for any damage to property or injury to persons engaging in procedures described within this manual. Persons engaging in any service to the product described herein do so entirely at their own risk Printed in the USA Copyright 2003 Konrad, Inc. Pictures and Technical Data: Randall Sofie Illustrations: David Scott

500 Series Technical Manual - iii - October 2009

TABLE OF CONTENTS

Chapter 1 Page GENERAL STERN DRIVE INFORMATION . . . . . . . . . . . 1-1

Hazard Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Consumer Questions and Concerns . . . . . . . . . . . . . . . 1-4 Weights, 500 Series Stern Drives . . . . . . . . . . . . . . . . . 1-5 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Overall Drive Specifications . . . . . . . . . . . . . . . . . . . . . 1-7 Torque Specifications for Fasteners 520 Gear Ratio Specifications 540 Gear Ratio Specifications 560 Gear Ratio Specifications Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Steering Recommendations . . . . . . . . . . . . . . . . . . . . . . 1-10 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Chapter 2 TOOLS AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Tool/Gauge Order Form . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Chapter 3 520 LOWER GEAR HOUSING ASSEMBLY

(Right Hand) . . . . . . . . . . . . . . . . . . . . . . . 3-1 Drawing #30-061M Building 520 Lower Gear Housing . . . . . . . . . . . . . . . . 3-3

500 Series Technical Manual - iv - October 2009

Chapter 4 Page 520 LOWER GEAR HOUSING ASSEMBLY

(Left Hand) . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Drawing #30-007M Building 520 Lower Gear Housing . . . . . . . . . . . . . . . . 4-3

Chapter 5 DISASSEMBLY OF 520 LOWER GEAR HOUSING . . . 5-1 Tearing Down 520 Lower Gear Housing . . . . . . . . . . . 5-2

Chapter 6 500 Series UPPER GEAR HOUSING ASSEMBLY . . . . 6-1 Drawing #30-006M Drawing #30-445M Building 500 Series Upper Gear Housing . . . . . . . . . . . 6-3

Chapter 7 500 Series UPPER GEAR HOUSING DISASSEMBLY. . 7-1 Tearing Down 500 Series Upper Gear Housing . . . . . . . 7-3

500 Series Technical Manual - v - October 2009

Chapter 8 Page TRANSOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Drawing #30-003M Drawing #30-004M Drawing #30-005M Building Transom Assembly . . . . . . . . . . . . . . . . . . . . . 8-3

Chapter 9 GIMBAL HOUSING BEARING CARRIER ASSEMBLY . 9-1 Drawing #30-019 Drawing #30-044M Building Gimbal Housing Bearing Carrier . . . . . . . . . . . 9-3

Chapter 10 TRIM PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Drawing #30-002

Drawing #30-186 Building Trim Pump Assembly . . . . . . . . . . . . . . . . . . . . 10-3

Chapter 11 540 LOWER GEAR HOUSING ASSEMBLY (Left Hand) 11-1 Drawing #30-052M Building 540 Lower Gear Housing . . . . . . . . . . . . . . . . . 11-3

500 Series Technical Manual - vi - October 2009

Chapter 12 Page 540 LOWER GEAR HOUSING ASSEMBLY (Right Hand) 12-1 Drawing #30-047M Building 540 Lower Gear Housing . . . . . . . . . . . . . . . . . 12-3

Chapter 13 560 LOWER GEAR HOUSING ASSEMBLY . . . . . . . . . . . 13-1 Drawing #30-552M Building 560 Lower Gear Housing . . . . . . . . . . . . . . . . . 13-3

500 Series Technical Manual 1- 1 October 2009

General Information

Chapter 1

General Information


General Information

HAZARD SYMBOL!

This manual has incorporated the use of international HAZARD symbols to alert service personnel when special instructions are required at a specific step or procedure.

! CAUTION

Hazards and practices which have the potential to cause injury to personnel, product or to damage property, will be identified using this marker.

Attention Manual Users

This manual has been published by Konrad, Inc. as a guide to mechanics and service personnel for working on the 500 Series stern drives. Konrad assumes that these personnel are familiar with the service of this product, or that of similar products, before attempting any work. Service personnel should possess the recommended training and necessary hand tools before any service is performed. Konrad could not conceivably know of all possible procedures to which service can be performed on this product, or of all the hazards of any particular method. Any person using procedures not recommended by Konrad in this manual, should first completely satisfy oneself that neither they nor the product will be endangered.


General Information

! CAUTION

Diesel engines contain electrical components that are not external ignition protected. DO NOT USE OR STORE GASOLINE ON BOATS THAT ARE EQUIPPED WITH DIESEL ENGINES, UNLESS PREVENTATIVE MEASURES HAVE BEEN MADE TO EXLUDE GASOLINE VAPORS FROM THE ENGINE COMPARTMENTS. Konrad stern drives have been designed and manufactured to use electrical systems that comply with U.S Coast Guard standards to minimize the risks of fire and explosions. All replacement parts on electrical systems should comply with U.S. Coast Guard regulations to minimize the risk of possible fire or explosion hazards. For safest results, use only Konrad suggested replacement parts, or those approved by the U.S. Coast Guard. Extreme care in installation should be observed, so that all electrical components are properly installed and tightened to reduce the risk of spark and the ignition of vapors.


General Information

Consumer Questions and Concerns

contact:

Konrad, Inc. 1421 Hanley Road

Hudson, Wisconsin 54016-9376 USA

Factory 1-715-386-4203 FAX 1-715-386-4219 Sales 1-800-927-3545

E-mail [email protected] Website http://www.konradmarine.com

Made with pride in the USA


General Information

Weights

520 Stern Drive Item Description 520 Weight

Trim cylinders with anchor pins 26 lbs 11.8 kg Trim pump 13 lbs 5.9 kg Upper housing assembly 100 lbs 45.4 kg Lower housing assembly 88 lbs 39.9 kg Transom assembly (with inner transom plate) 88 lbs 39.9 kg Total Dry Weight 315 lbs 142.9 kg






General Information

Safety Precautions

! CAUTION

Read and understand all safety precautions and warnings before performing any repairs. This list contains the general safety precautions that must be followed to provide personal safety. Additional safety precautions are included within the procedures where applicable.

• Make sure that work area surrounding the product is safe. Be aware of hazards and dangerous conditions that may exist.

• Always wear protective eye and footwear while working.

• Avoid wearing loose-fitting and torn clothing that may become caught in

machinery or moving parts. • Use hoist or other proper lift assistance whenever necessary. Always verify the

condition and capacity of the equipment to perform the task. Never risk personal injury by attempting to lift alone.

• Do not use lifting jacks or hoists as the only support when working on the

product. Always use the appropriate stands and blocks when servicing the product and it’s components.

• Only use the appropriate tools in good condition and be familiar with their correct

usage before attempting any service to the product.

• Always use the correct fasteners and replacement parts when performing repairs and service. Never use lesser quality or used replacement parts when new parts are required.


General Information

Overall Drive Specifications Listed below are the torque specifications for those fasteners that have a specified torque value. Securely tighten all other fasteners.

Torque Specifications for Fasteners

520 Gear Ratio Specifications

Overall Gear Ratio

Drive Shaft Housing Gear Teeth Number

(Drive/Driven)

Gear Housing Gear Teeth Number

(Drive/Driven) 1.30 : 1 22 / 19 16 / 24 1.43 : 1 22 / 21 16 / 24 1.57 : 1 21 / 22 16 / 24 1.79 : 1 21 / 25 16 / 24 2.00 : 1 24 / 32 16 / 24

540/560 Gear Ratio Specifications

Overall Gear Ratio

Drive Shaft Housing Gear Teeth Number

(Drive/Driven)

Gear Housing Gear Teeth Number

(Drive/Driven) 1.09 : 1 22 / 19 15 / 19 1.21 : 1 22 / 21 15 / 19 1.33 : 1 21 / 22 15 / 19 1.51 : 1 21 / 25 15 / 19 1.69 : 1 24 / 32 15 / 19

Description Torque Value Drive Shaft Flange to Transmission

Output Flange Shaft Nuts/Bolts 35 lb-ft (48 Nm)

Gimbal Housing Stud to Inner Transom Plate Nuts 25-30 lb-ft (34-41 Nm)

Drive Shaft Housing to Gear Housing Nuts and Bolts 35 lb-ft (48 Nm)

Power Trim Cylinder to Anchor Pin, Nut

Tighten until approximately two (2) threads show - Do not over tighten

Propeller Nut 80 lb-ft (109 Nm) Top Cover Bolts (and Emergency Tiller Arm Bracket if applicable) 20 lb-ft (27 Nm)

Adapter Plate Bolts and Nuts 35 lb-ft (48 Nm) Stern Drive Unit to Bell Housing

Attaching Nuts 55 lb-ft (74 Nm)

Gimbal Carrier Bolts 70 lb-ft (94.9 Nm)


General Information

Propeller Installation WARNING: Remote Control must be in NEUTRAL, the engine must be turned off and ignition key removed from switch before removing and/or installing propeller.

Model 520 Model 540

Description Qty Part # a Prop shaft (L) OR 1 10-360 Prop shaft (R) 1 10-363 b Forward thrust hub 1 10-292 c Propeller 1 variabled Spline washer 1 10-293 e Tab washer 1 10-295 f Propeller nut 1 10-296

Description Qty Part # a Prop shaft (L) OR 1 10-677 Prop shaft (R) 1 10-596 b Propeller 1 variablec Prop Hardware Kit 1 10-680 d Propeller Nut 1/0 10-667


General Information

Model 560 When using a stainless steel propeller, care must be taken to ensure continuity between the propeller and the propeller shaft, or corrosion of the drive components will occur. Periodic removal of the propeller, a thorough cleaning of all components, and correct lubrication will help maintain good continuity and extend propeller and drive unit life.

Description Qty Part # a Forward prop shaft 1 12-502 b Forward thrust hub 1 12-509 c Forward propeller 1 variable d Forward prop nut 1 30-554 e Rear prop shaft 1 12-503 f Rear thrust hub 1 12-508 g Rear propeller 1 Variable h Rear prop nut 1 12-529


General Information

Steering Recommendations

Konrad stern drive assemblies do not include steering systems. The boat builder may choose a steering system suitable to the boat application. Internal hydraulic steering is usually used for most sport boat and light commercial applications. The use of an external power steering system works better for heavy commercial, continuous duty or high-speed single or twin-engine applications, and/or boats with unusual handling characteristics. Due to the many variables involved, the final decision on a steering system should be based upon the boat manufacturer’s recommendations, and after thorough testing of the specific boat model. If there is any question whether or not external power steering should be used, Konrad suggests that it be installed. External power steering and hydraulic helm systems can be obtained from many sources. For your convenience, several suppliers are listed here:

Latham Marine, Inc. Teleflex Canada 280 SW 32nd Court 3831 N 6 Rd Fort Lauderdale, FL 33315 Richmond, BC Canada V6V1P6 954-462-3055 604-270-6899

Marine Machine, Inc. Warlock Performance Marine 12890 NW 30th Avenue 392 Elizabeth Lane Opa Locka, FL 33054 Corona, CA 92880 305-681-1815 909-371-8247


General Information

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 first 10 hours

Stern Drive Unit Oil (Change)

Standard Oil - EVERY 200 HOURS Synthetic Oil - EVERY 400 HOURS

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 (Grease) Replace Every 200 Hours for Heavy Use Replace Every 1000 Hours for Light Use

Universal Joints (Replace) X 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

Tools and Gauges

500 Series Technical Manual 2-1 September 2009

Chapter 2

Tools andGauges

Tools and Gauges


TO = Tools Bearing Driver

Konrad #TO-017

Tool Description: Installs bearing races into lower drive housings.

Tool Used In:520 / 540 Lowers

Bearing Driver

Konrad #TO-019

Tool Description: Installs needle bearing into lower bearing carrier.

Tool Used In:520 Lower

Bearing Driver

Konrad #TO-021

Tool Description: Used with #T0-022 to install vertical bearing race.


Tools and Gauges


Bearing Driver AssemblyKonrad #TO-022

Tool Description: Used to seat lower bearing race for the vertical shaft in the lower gear housing.


Bearing Driver

Konrad #TO-023

Tool Description: Removes bearing races from lower drive housing.


Bearing Driver

Konrad #TO-025

Tool Description: Installs bearing races into upper drive shaft housing, 520 LH lower and RH carrier.

Tool Used In:500 Series Uppers520 LowerGimbal Carrier

Tools and Gauges


Slide Hammer

Konrad #TO-028

Tool Description: Used to remove bearing races.

Tool Used In:500 Series Uppers500 Series Lowers

Cover Nut Wrench Konrad #TO-029

Tool Description: Used to install and remove cover nut (10-242) in lower drive housing.


Seal Driver

Konrad #TO-030

Tool Description: Used to install grease and water seals.


Tools and Gauges


Bearing Driver

Konrad #TO-031

Tool Description: Used for installing smaller diameter bearing races and front seal in upper housings.

Tool Used In:500 Series Uppers

Universal Puller Plate

Konrad #TO-032

Tool Description: Removes bearings in lower and upper drive units.


Socket WrenchKonrad #TO-033

Tool Description: Used for fastening Konrad Lock Nut (10-573) in lower housing and Lock Nut (10-576) in upper housing.


Tools and Gauges


Spline SocketKonrad #TO-034

Tool Description: Used on gear shafts for assembly and disassembly.


Bearing Puller

Konrad #TO-035

Tool Description: General puller used with several Konrad tools.


Alignment PlateKonrad #TO-036

Tool Description: Guides driving rod when installing race into nose of the lower housing.


Tools and Gauges


Impact Rod

Konrad #TO-037

Tool Description: Installs bearing races.


Bearing Driver

Konrad #TO-040

Tool Description: Installs top vertical bearing race into lower.


Bearing Driver

Konrad #TO-041

Tool Description: Used with tool #T0-035 to install bottom vertical bearing race.


Tools and Gauges


Bearing Driver

Konrad #TO-042

Tool Description: Installs bearing races into the bearing carrier of the lower.


Seal Driver

Konrad #TO-043

Tool Description: Installs seals into seal carrier.


Bearing Driver

Konrad #TO-047 and #TO-047A

Tool Description: Removes bearing race from the nose of lower.


TO-047

TO-047-A

Tools and Gauges


Bearing Driver

Konrad #TO-049

Tool Description: Removes needle bearing from lower housing.


Bearing Driver


Tool Description: Used to remove bearing race from nose of lower housing.


Spanner Socket

Konrad #TO-051

Tool Description: Installs seal carrier(10-678) into lower housing.


TO-050

TO-047-A

Tools and Gauges


Cover Nut Wrench

Konrad #TO-052

Tool Description: Used to Install and remove cover nut (10-607) in lower housing.


Alignment Plate

Konrad #TO-053

Tool Description: Guides driving rod when installing race into the nose of the lower housing.


Spanner Socket

Konrad #TO-054

Tool Description: Installs retainer nut (10-613).


Tools and Gauges


Bearing Driver

Konrad #TO-057

Tool Description: Installs bearing over shaft in bearing carrier.

Tool Used In:Gimbal carrier

Bushing Driver

Konrad #TO-059

Tool Description: Installs upper bushing for steering shaft into transom.

Tool Used In:Transom assembly

Bushing Driver

Konrad #TO-060

Tool Description: Installs lower steering shaft bushing into transom.

Tool Used In:Transom assembly

Tools and Gauges


Bushing Driver Konrad #TO-062

Tool Description: Installs bushing into gimbal Ring and seal into transom.

Tool Used In:Gimbal ringTransom assembly

Seal Aligner

Konrad #TO-064

Tool Description: Installs seal to correct height in Gimbal Carrier Driver (10-473).


Torque Wrench Adapter

Konrad #TO-066

Tool Description: Used to tighten SHCS (11-190) in the 30-226 Rubber Coupling Driveshaft.

Tool Used In:Rubber Coupling Driveshaft (30-226)

Tools and Gauges


Torque Wrench Adapter, 7/8”

Konrad #TO-067

Tool Description: Used to tighten HHCS (10-486) on the Rubber Coupling Driveshaft(30-226).


Torque Wrench Adapter, 22 mm

Konrad #TO-068

Tool Description: Used to tighten M16 bolts on the Rubber Coupling Driveshaft(30-226).


Bearing Race Driver

Konrad #TO-070

Tool Description: Installs bearing race into gimbal carrier.


Tools and Gauges


Drive Stand Base Unit

Konrad #TO-075

Tool Description: Used to hold the Lower Stand Unit (TO-076) and the Upper Stand Unit (TO-077).


Lower Stand

Konrad #TO-076

Tool Description: Attaches to the Drive Stand Base Unit (TO-075) and holds the Lower Housing for assembly.

Tool Used In:500 Series Lowers

Upper Stand

Konrad #TO-077

Tool Description: Attaches to the Drive Stand Base Unit (TO-075) and holds the upper housing for assembly.

Tool Used In: 500 Series Uppers

Tools and Gauges


Spanner Wrench

Konrad #TO-079

Tool Description: Used to install Locking Nut (11-585).


Race Remover

Konrad #TO-080

Tool Description: Removes Bearing Race (10-267) from standard upper


Tailpiece Aligner Konrad #TO-094

Tool Description: Aligns tailpiece unit (30-273).

Tool Used In:500 Series Sterndrives

TO-094-A

TO-047-B

Tools and Gauges


Drive Shaft Aligner

Konrad #TO-096

Tool Description: Used for correct alignment of driveshaft.

Tool Used In:Rubber Coupling Driveshaft (30-226).

Spanner Wrench

Konrad #TO-098

Tool Description: Used to install and remove locknuts (12-033 and 12-034) upper housings.

Tool Used In:500 Series HD Uppers

Seal Driver

Konrad #TO-100

Tool Description: Used with impact rod (TO-037) to install front seal in HD upper housings.


Tools and Gauges


Bearing Remover

Konrad #TO-101

Tool Description: Removes front bearing race from HD upper housing.


Bearing Driver

Konrad #TO-102

Tool Description: Used with impact rod (TO-037) to install front bearing race in HD upper housing.


Pressure Tester

Konrad #TO-103

Tool Description: Used to test pressure in the 500 Series Sterndrives

Tool Used In:500 Series Sterndrives

Tools and Gauges


Backlash Checker

Konrad #TO-105

Tool Description: Used to check the backlash in the X-Factor lower.

Tool Used In:X-Factor Lower

Bearing Driver/Remover

Konrad #TO-107

Tool Description: Installs and removesneedle bearing #12-522 from carrier #12-510.


Race Driver

Konrad #TO-109

Tool Description: Installs bearing race#12-519 into nose of lower housing #12-500.


Tools and Gauges


Race Driver/Remover

Konrad #TO-110Tool Description: Installs and removes bearing race #12-522 from forward propeller shaft #12-502


Bearing Driver


Tool Description: Removes bearing race #12-519 from the nose of lower housing #12-500. Use #TO-035 (without hooks) to pull #TO-047A.


Gear Support

Konrad #TO-112

Tool Description: Supports gear #12-501 in order to press bearing #12-521 onto hub and not damage gear teeth.


TO-111

TO-047-A

Tools and Gauges


Bearing Driver

Konrad #TO-113

Tool Description: Installs bearing #12-519 onto hub of gear #30-553 and installs bearing #12-521 onto hub of gear #12-501.


Bearing Driver

Konrad #TO-114

Tool Description: Installs needle bearing #12-520 into forward propeller shaft #12-502.


Race Driver

Konrad #TO-115

Tool Description: Used to press needle bearing race #12-520 onto rear propeller shaft #12-503. Also can be used to press roller bearing race #10-653 onto vertical shaft #12-511.


Tools and Gauges


Seal Driver

Konrad #TO-116

Tool Description: Used to press seals #12-525 and #12-517 to their correct depths into forward propeller shaft #12-502.


Seal Driver

Konrad #TO-117

Tool Description: Used to press seals #12-526 and #12-518 to their correct depths into bearing carrier #12-510.


Spanner Wrench

Konrad #TO-118

Tool Description: Installs and removes carrier #12-510 from lower housing #12-500.


Tools and Gauges


Spanner Wrench

Konrad #TO-119

Tool Description: Installs and removes retaining nut #12-513 from lower housing #12-500.


Prop Nut Wrench

Konrad #TO-121

Tool Description: Installs propeller nut #30-554. This will cinch the forward propeller to the thrust hub #12-509 on the forward prop shaft #12-502.


Tools and Gauges


GO = Gauges

Gauge

Konrad #GO-013

Tool Description: Used with GO-024 to check gap spacing and gear height in the upper gear housing.


Gauge

Konrad #GO-014

Tool Description: Used in upper gear housing to measure gap spacing of gear on horizontal shaft.


Gauge

Konrad #GO-015

Tool Description: Used with GO-024 to check gear height and component spacing in lower housing.


Tools and Gauges


Indicator Rod

Konrad #GO-016

Tool Description: Used to check backlash in lower housing.


Dial Indicator

Konrad #GO-017

Tool Description: Used to indicate backlash measurement (0.000-1.000 inches at .001 increments).

Tool Used In:500 Series Upper500 Series Lower

Gimbal Ring Alignment Gauge

Konrad #GO-018

Tool Description: Inserted into upper bearing carrier when adjusting gimbal ring height.

Tool Used In:Gimbal assemblyTransom assembly

Gauge

Tools and Gauges


Konrad #GO-020

Tool Description: Used to check gear height and component spacing in lower housing.


Gauge

Konrad #GO-024

Tool Description: Used as a handle on the GO-013 and GO-015.

Tool Used In:500 Series Uppers520 Lower

Pinion Height Gauge

Konrad #GO-025

Tool Description: Used to check pinion (#11-639) height and component spacing in lower housing (#12-500).


Tools and Gauges


Backlash Gauge

Konrad #GO-026

Tool Description: Used to check backlash on rear propeller shaft #12-503 between gear #30-553 and pinion #11-639.


Backlash Gauge

Konrad #GO-027

Tool Description: Used to check backlash on forward propeller shaft #12-502 between gear #12-501 and pinion #11-639.


Tools and Gauges


To the Service Technician:This page has been inserted to provide a list of tools that may be required if the licensed service center has not already purchased a Tool Package. Use the tooling section preceding this page to identify the tool name and part numbers required, then record it on this page. Contact Konrad Marine for tool prices and ordering information. Insert a copy of this page when ordering by mail or fax (715-386-4219).

Tool/Gauge Order FormTool/Gauge Name Part Number Quantity Price

Bearing Driver TO-017

Bearing Driver TO-019Bearing Driver TO-021

Bearing Driver Assembly TO-022Bearing Driver TO-023Bearing Driver TO-025Slide Hammer TO-028

Cover Nut Wrench TO-029Seal Driver TO-030

Bearing Driver TO-031Universal Puller Plate TO-032

Socket Wrench TO-033Spline Socket TO-034Bearing Puller TO-035

Alignment Plate TO-036Impact Rod TO-037




Seal Driver TO-043Bearing Driver TO-047Bearing Driver TO-047ABearing Driver TO-049Bearing Driver TO-050Spanner Socket TO-051

Tools and Gauges


Tool/Gauge Name Part Number Quantity PriceCover Nut Wrench TO-052

Spanner Socket TO-054




Bushing Driver TO-059

Bushing Driver TO-060

Bushing Driver TO-062Seal Aligner TO-064

Torque Wrench Adapter TO-066

Torque Wrench Adapter, 7/8” TO-067

Torque Wrench Adapter, 22 mm TO-068

Bearing Race Driver TO-070

Drive Stand Base Unit TO- 075

Lower Stand TO-076

Upper Stand TO-077

Spanner Wrench TO-079

Race Remover TO-080

Rod Alignment Tool TO-094A

Boss Alignment Tool TO-094B

Drive Shaft Aligner TO-096


Seal Driver TO-100

Bearing Remover TO-101


Pressure Tester TO-103

Backlash Checker TO-105

Bearing Driver/Remover TO-107

Tools and Gauges


Tool/Gauge Name Part Number Quantity PriceRace Driver TO-109

Race Driver/Remover TO-110


Gear Support TO-112



Race Driver TO-115

Seal Driver TO-116

Seal Driver TO-117



Prop Nut Wrench TO-121

Gauge GO-013

Gauge GO-014

Gauge GO-015

Indicator Rod GO-016

Dial Indicator GO-017

Gimbal Ring Alignment Gauge GO-018Gauge GO-020

Handle GO-024

Pinion Height Gauge GO-025

Backlash Gauge GO-026

Backlash Gauge GO-027


520 Lower Gear Housing Assembly (Right Hand)

Chapter 3

520 LOWER GEAR

HOUSING ASSEMBLY

(Right Hand)



! Notice

To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a 500 Series stern drive, it is suggested that all reassembly be done using the same shim set-up as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled. * Note: Loctite 271 or equivalent requires 24 hours to cure.

DATE

Konrad

DRAWING NUMBER

NEXT ASS'Y

30-061M

.020

SYM REVISIONDRAWING NO. 30-061M DR

DO NOT SCALE DRAWING

1:2.5

6/22/0672.89LBSWEIGHT: DATE:

TITLE:

TOLERANCE

MAT'L:

520 LOWER GEAR HOUSING ASS'Y, R.H.

DRAWN BY: LH

.XXX

SCALE:

.005

.XXAPP.BY:

.010

.X

THIS DOCUMENT AND THE INFORMATIONCONTAINED HEREIN IS CONFIDENTIALAND PROPRIETARY PROPERTY AND MUSTNOT BE USED, REPRODUCED, OR ITSCONTENT DISCLOSED, IN WHOLE OR INPART, WITHOUT PRIOR WRITTEN CONSENTOF KONRAD MARINE.

25

5

12

11

44

4

3

5

238

40

7

5

6

10

9

8

32

42

31

30

1

43

31

34

33

35

41

39

36

37

45

15

14

13

16

17

18

19

20

21

22

23

24

26

29

27

28

3

45 10-508 SLINGER, OIL 144 30-205 SET, LOCKNUT 143 10-457 WASHER, FLAT 642 10-313 STUD 641 10-334 NUT 140 10-496 STUD 139 10-433 PLATE, INHIBITOR 238 10-432 PLATE, INHIBITOR 137 10-333 NUT 436 10-253 STUD 435 10-461 F.H.C.S. 234 10-155 PLUG, DRAIN, MAGNETIC 133 10-285 WASHER, SEAL 132 10-399 O-RING 131 10-314 NUT 730 10-279 STUD 129 10-293 WASHER, SPLINED 128 10-296 LOCKNUT, NYLON 127 10-295 WASHER, TAB 126 10-292 THRUST HUB 125 10-017 KEY 124 10-242 COVER, NUT 123 10-203 WASHER, TAB 122 10-639 SEAL 121 10-291 SEAL 120 10-394 BEARING, ROLLER 119 10-364 CARRIER, BEARING 118 10-290 O-RING 117 10-499 WASHER, THRUST 116 10-289 LOAD RING 115 10-269 BEARING 114 10-258 GEAR, HORIZONTAL 113 10-363 SHAFT, PROP, RH 112 10-400 O-RING 111 10-397 SLEEVE, ALIGNMENT 110 10-261 PINION, VERTICAL 19 10-358 WASHER, BELLEVILLE 18 10-260 LOCKNUT, STAKE 17 10-557 SPACER, LOWER HSG 16 10-377 PINION BEARING 15 10-288 SET, SHIM 34 10-526 WASHER, TONGUED 13 10-259 BEARING 22 10-200 SHAFT, VERTICAL, BOTTOM 11 10-245 520 LOWER HOUSING 1

ITEM NO. PART NO. DESCRIPTION QTY.

*

*

402-03 TES RAEG SA DLOS *

RAEG REWOL DRADNATS A SI SIHT ** ,YSSA MOTSUC A SI SRUOY FI ,YSSA

OT YROTCAF EHT TCATNOC ESAELP STNENOPMOC TCERROC YFIREV

LOWERGEARHOUSINGRH ASS’Y


520 Lower Gear Housing Assembly (Right Hand) Figure 3-1

Start to rebuild the lower gear housing (10-245) by first inspecting the casting for any damage or defects. Next, thoroughly clear any sediment, metal shavings or debris that may be adhered to internal surfaces or hidden in pockets or cavities. Best results can be achieved by using compressed air and a dry rag, as demonstrated in figure 3-1.



Onto vertical gear shaft (10-200), slide over bearing (10-259) so that it is orientated as seen in figure 3-2. Once bearing has been installed, place tongued washer (10-526) over top of gear shaft as shown in drawing 3-1 below. Drawing 3-1

Figure 3-3

At top of shaft, fasten on first half of lock nut (10-573)*. See figure 3-3.

* First nut of assembly is placed with chamfered corners face down as shown in drawing 3-2. Drawing 3-2


520 Lower Gear Housing Assembly (Right Hand) Figure 3-4 Figure 3-5 Figure 3-6

To begin assembly, place .020 in (.51 mm) shims (10-288) and bearing race (10-377) into seat at bottom of housing as shown in figures 3-4 through 3-6. Lubricate race with 90w oil for ease of installation. Refer to diagram 3-1 for correct tools and orientation required to install bearing race. Tools required for this procedure are bearing driver (TO-021) and bearing driver assembly (TO-022). Diagram 3-1

A: Nut (TO-022) B: Locating Disk (TO-022) C: Casting (10-245) D: Drive Screw

(TO-022) E: Shims (10-288) F: Bearing Race

(10-377) G: Bearing Driver

(TO-021) Place tools as seen in diagram and turn nut clockwise to pull bearing race into housing to properly seat bearing race.

AB

CD

EFG



As shown in figure 3-7, lubricate the upper bearing race (10-259) with 90w oil and drive into seat as shown. Use bearing driver (TO-017) and impact rod (TO-037) to ensure that race is installed correctly. Refer to figure 3-8 for correct installation of race.

Figure 3-8



Figure 3-9 Through top of gear housing, insert upper bearing and vertical gear shaft assembly so splines and threads are visible as shown in figure 3-9 and 3-10 below. Figure 3-10

Figure 3-11 While holding shaft in place, rotate gear housing to install lower bearing (10-377) to vertical gear shaft. Splines and threads will show when bearing is pushed on correctly. Refer to figure 3-11 and drawing 3-3 for assistance. Drawing 3-3



Figure 3-12

! CAUTION This procedure may not be the final time that the lock nut is fastened to the vertical shaft. Post procedures may require that shim adjustments be performed to this vertical shaft’s bearing sets. If adjustments are required, then the nut will need to be removed. This lock nut has been designed to be applied safely only ONE TIME, and should never be reused for operation of the drive. It is required that the assembler obtain two lock nuts to rebuild this part of the stern drive. Use one lock nut for all adjustments and the other for final installation once all adjustments have been performed.

Figure 3-13 As shown in figure 3-12, slide pinion gear (10-261) onto splines at bottom of vertical shaft. Secure gear to shaft with washer (10-358) and lock nut (10-260) as shown in figure 3-13. After all adjustments have been made, at the final installation, apply *Loctite 271 or equivalent to threads of lock nut.

New Used

New lock nut will still retain its oval thread hole, while used nut will have been rounded

. after being applied once.



Figure 3-14 Double checking that the first part of upper lock nut system has been fastened down hand tight, proceed by placing spline socket (TO-034) over splines as shown in figure 3-14. Over end of spline socket, use an appropriate torque wrench to turn shaft and fasten lock nut (10-260) at bottom to 150 lb-ft (203 Nm) as shown in figure 3-15.

Figure 3-15



Once the lock nut has been secured to shaft, proceed by measuring rolling torque with gauge as demonstrated in figure 3-16. Rolling torque measurements should range from 10-12 lb-in (1.13-1.36 Nm) when properly set.

Figure 3-17

To adjust rolling torque, set tools up as shown in figure 3-17. Use socket wrench (TO-033) over nut and spline socket (TO-034) to tighten or loosen the nut to adjust rolling torque.



Through bottom opening of gear housing, insert gauge (GO-015) to check gap of pinion gear. Refer to figure 3-18 for assistance in set up of measurement. Using a feeler gauge, as shown in figure 3-19, check gap of pinion gear.

Figure 3-19

Ideal gap should range from .024-.026 in (.61-.66 mm). If gap needs to be increased, then decrease the amount of shims that are at the bearing race. If gap needs to be decreased, then shims are added. When making these adjustments, the pinion gear and nut will have to be removed in order to access the bearing race. Be sure to reassemble all parts as described in figures 3-12 through 3-18. When rebuilding a drive unit, try to use the exact amount and size of shims that were taken out. This will minimize the amount of adjustments that may need to be made and reduce the number of

times that the bearing race is removed and replaced.


520 Lower Gear Housing Assembly (Right Hand) Figure 3-20 Drawing 3-4

bearingrace

shim

Into the nose cone, place .015 in (.38 mm) shim (10-288) in front of bearing race (10-259) as shown in figures 3-20, 3-21 and drawing 3-4 . Use bearing driver (TO-017), alignment plate (TO-053) and impact rod (TO-037) to correctly install bearing race,

lubricated with 90w oil, into nose cone.

Figure 3-21 The diagram 3-2 below illustrates an order of parts that are assembled over the next few steps.

A: Bearing race (10-394) B: Bearing (10-269) C: Gear (10-258) D: Propeller shaft (10-363) E: Oil slinger (10-508) F: Bearing (10-259)

Diagram 3-2

A B C D E F



Press bearing (10-269) onto gear (10-258). Lubricate mating surfaces with 90w gear oil before pressing the two (2) components together. Refer to figure 3-22.

! CAUTION

inner surface

Figure 3-23

Figure 3-23 shows bearing pressed correctly on the gear. When assembling gear and bearing cluster, always press components together using the inside ring of the bearing. Never apply force to any other surfaces as damage may result to rollers or retainer on bearing. Use an electric or hydraulic press to properly combine components if available.



Press gear and bearing assembled in previous assembly step onto propeller shaft (10-363). Refer to figure 3-24 for visual description of component orientation on shaft.

Figure 3-25

Press gear and bearing onto propeller shaft using hydraulic press as shown in figure 3-25.

Figure 3-26

Proper assembly will have gear and bearing seated firmly against ridge on shaft. Refer to figure 3-26 for complete installation of gear and bearing to shaft.



As shown in figure 3-27, press oil slinger (10-508) on propeller shaft until firmly seated against shoulder.

Figure 3-28

With oil slinger in place, proceed by pressing on bearing (10-259) as demonstrated in figure 3-28. Lubricate shaft surface before installing bearing.



Press needle bearing race (10-394) over end of propeller shaft so that the two (2) holes shown in figure 3-29 are aligned.

Drawing 3-5

! CAUTION

To prevent damage and minimize wear, keep holes aligned when installing bearing race. This alignment will ensure that proper oil flow through shaft and bearings is created when shaft is in motion, as shown in drawing 3-5. Do not press race beyond ridge of shaft. Severe risk of metal fatigue and flying debris may result from part shattering.

Needle Bearing

Oil Passage WayPropeller Shaft

Oil Passage Hole

Bearing Race



Install propeller shaft assembly into lower gear housing as shown in figure 3-30.

Figure 3-31

Notice: The next few procedures will demonstrate a complete overhaul of the lower bearing carrier, shown in figure 3-31. If bearings and races in carrier are suitable for reuse, then only follow procedure for replacement of seals. Never reuse carrier seals if grease and water seals have been exposed to more than two hundred (200) hours of operation.



Obtain lower bearing carrier (10-364) and inspect for damage before continuing assembly.

Figure 3-33

Using bearing driver (TO-019), install needle bearing (10-394) into carrier as shown in figures 3-33 through 3-35 and drawing 3-6. Apply 90w gear oil to bearing on all surfaces before installing into the carrier.


520 Lower Gear Housing Assembly (Right Hand) Drawing 3-6 Figure 3-34

Figure 3-35



Install right hand rotation prop shaft’s bearing race (10-269) into carrier using bearing driver (TO-025) as shown in figure 3-36.

Figure 3-37

Proper installation will have the taper of the bearing race facing outward, as shown in figure 3-37.



Using seal driver (TO-030), press seal #1 (10-291) and seal #2 (10-639) into bearing carrier as shown in figure 3-38. To install correctly, slide on two (2) seals at opposite ends of the seal driver. Verify that seals oppose one another while resting on seal driver, and that rubber gaskets rest against circular ridge before installing into carrier. Around outside surface of each seal, apply thin layer of *Loctite 271 or equivalent to lock seal in place. Refer to diagram 3-3 for assistance regarding installation of seals into the bearing carrier.

Diagram 3-3

Step #1 Step #2

Seal Driver

Carrier

Press in seal #1 and flip tool over to install seal #2

TO-030

10-63910-291


520 Lower Gear Housing Assembly (Right Hand) Figure 3-39 Figure 3-40

Once seals are in place, apply grease to them and slide carrier over propeller shaft as seen in figure 3-39. Place tab washer (10-295) on top of carrier as shown in figure 3-40. Next, apply oil to cover nut (10-242) threads, then fasten into lower gear housing as shown in figure 3-41. Tighten cover nut into lower gear housing using cover nut wrench (TO-029). Tighten nut until all movement (back and forth) of the propeller shaft is eliminated. Figure 3-41 Figure 3-42



Place indicator rod (GO-016) onto top of vertical drive shaft to verify backlash of gears. Set dial indicator (GO-017) perpendicular to indicator rod. Set probe tip of dial indicator on mark (II) of the indicator rod, as shown in figure 3-43. Verify that propeller shaft (10-363) is secure from movement by tightening cover nut until no shaft rotation occurs. Place hand at top of vertical shaft and turn back and forth lightly to feel gear mesh. Find where gears touch and set indicator. Next, turn shaft slowly until gears come in contact with each other again. The amount of movement that occurs between gear contact is the gap spacing or backlash.

Spacing should be .017-.021 in (.43-.53 mm) when properly set. If adjustments are

required, shimming will need to be performed at the nose cone bearing race. Refer to figure 3-20 and drawing 3-4.

Figure 3-44

To make adjustments, disassemble lower drive unit, using Chapter 5 for assistance. Remove bearing race and adjust with appropriate shims, (more shimming will increase backlash, less shimming will decrease backlash) then replace all removed components and recheck backlash. Note: Several adjustments to the shims may need to be made in order to properly set the backlash of the gears. A trial and error approach may need to be performed before the proper backlash can be achieved.



When backlash of gears has been properly set, remove cover nut and bearing carrier from lower housing. When removed, proceed by inserting load ring (10-289) into opening at bottom of lower housing as demonstrated in figure 3-45. Note: Only install load ring for final assembly. Only install load ring after all other adjustments are made, and never reuse ring once it has been installed.

Figure 3-46

With load ring in place, proceed by placing thrust ring (10-499) into gear housing as shown figure 3-46. Note: Install thrust ring so that tapered end is facing down in the lower housing.



Apply grease between seals (10-291 and 10-639) and grease o-ring (10-290), then place in housing as shown in figure 3-47.

! CAUTION Drive unit may suffer serious damage if o-ring is omitted from installation. Always be sure that o-ring is properly placed before operating stern drive.

Figure 3-48

When load ring, thrust ring, and o-ring are in place, proceed by installing bearing carrier assembly into housing as shown in figure 3-48. Note: Make sure that key way is aligned before continuing to next step.



Using pliers or appropriate tool, insert key (10-017) into key way as shown in figure 3-49.

Figure 3-50

With key in key way, place tab washer (10-295) onto bearing carrier so that tabs are aligned in their respective slots as shown in figure 3-50. For easier assembly in the following steps, bend all square tabs up thirty degrees (30o) before installing cover nut.


520 Lower Gear Housing Assembly (Right Hand) Figure 3-51 Figure 3-52 Figure 3-53

If cover nut (10-242) is aluminum, apply anti-seize compound to threads before fastening into lower gear housing. If cover nut (10-242) is brass, lubricate with 90w oil before fastening into lower gear housing. Tighten cover nut into lower gear housing as shown in figure 3-51, using cover nut wrench (TO-029) as demonstrated in figure 3-52. Tighten nut until shaft has rolling torque ranging between 25-30 lb-in (2.82-3.39 Nm) as shown in figure 3-53. While tightening cover nut, periodically check rolling torque measurement, using spline socket (TO-034) and a rolling torque wrench, being sure not to exceed the maximum setting of 30 lb-in (3.39 Nm). When rolling torque has been adjusted to the correct setting, proceed by bending a tab into an aligning slot on the cover nut as demonstrated in figure 3-54. Never loosen nut to align tabs, as load ring will not expand to fill the gap created when nut is backed off. After one (1) tab is bent into slot, bend the other three (3) tabs down. Figure 3-54 Drawing 3-7

Turn retainer nut until tab is aligned,thenpry up to lockposition.



Proceed by removing first half of lock nut (10-573) by using socket wrench (#TO-033), and then bearing from shaft (10-200). When these parts have been removed, insert spacer tube (10-557) onto vertical gear shaft, as demonstrated in figure 3-55, and drawing 3-8. With spacer installed, replace bearing over shaft and fasten down with first half of lock nut. Tighten nut down to 150 lb-ft (203 Nm). After nut has been tightened, measure rolling torque on shaft as shown in figure 3-53 on the previous page. When properly set, torque should range between 25-30 lb-in (2.82-3.39 Nm). If adjustments to torque are required, then remove the upper

bearing race and add shims to increase the rolling torque resistance. Drawing 3-8

Note: This spacer does not exist in all 520 stern drive models made prior to 1999. It has been introduced as a product improvement and is suggested that it be included in older models when being rebuilt.



Next, fasten second half of lock nut (10-574) down so that the two (2) surfaces come in contact. Once surfaces come in contact as shown in figure 3-56, back nut off until holes are aligned. When holes are aligned, turn nut off 2/6 or two (2) holes counter clockwise. Next, fasten two (2) halves together using the six (6) set screws (10-578) that are part of the assembly. Tighten each screw to 75 lb-in (8.47 Nm) using a star pattern to fasten nuts together as demonstrated in diagram 3-4. Use *Loctite 271 or equivalent on set screws and nut when fastening final assembly together. Figure 3-57 shows these procedures completed.

Diagram 3-4 Figure 3-57

1

234

5

6



Install alignment sleeve (10-397) then o-ring (10-399) and o-ring (10-400) as shown in figure 3-58.

Figure 3-59

At nose of bullet on lower gear housing, install washer/gasket (10-285) and magnetic drain plug (10-155) until snug in housing.

520 Lower Gear Housing Assembly (Left Hand)

Chapter 4

520 LOWER GEAR

HOUSING ASSEMBLY

(Left Hand)

500 Series Technical Manual 4 - 1 October 2003


! Notice



.020

Konrad

DRAWING NUMBER

NEXT ASS'Y

30-007M

DATE SYM REVISION DR30-007MDRAWING NO.


1:2.5

6/22/0672.42LBSWEIGHT: DATE:

TITLE:

TOLERANCE

.XXX .005

SCALE:APP.BY:

.XX

MAT'L:

520 LOWER GEAR HOUSING ASS'Y, L.H.

DRAWN BY: LH

.010

.XTHIS DOCUMENT AND THE INFORMATIONCONTAINED HEREIN IS CONFIDENTIALAND PROPRIETARY PROPERTY AND MUSTNOT BE USED, REPRODUCED, OR ITSCONTENT DISCLOSED, IN WHOLE OR INPART, WITHOUT PRIOR WRITTEN CONSENTOF KONRAD MARINE.

*

*

* SOLD AS GEAR SET 30-204

** THIS IS A STANDARD LOWER GEAR ASSY, IF YOURS IS A CUSTOM ASSY, PLEASE CONTACT THE FACTORY TO VERIFY CORRECT COMPONENTS

LOWERGEAR HOUSINGLH ASS'Y

30

12

11

46

4

3

5

240

42

7

5

6

10

9

8

34

44

33

32

1

45

33

36

35

3743

41

38

39

16

15

14

13

18

19

20

17

21

22

23

24

25

26

28

31

2927

46 30-205 SET, LOCKNUT, K-70 145 10-457 WASHER, FLAT 644 10-313 STUD 643 10-334 NUT 142 10-496 STUD 141 10-433 PLATE, INHIBITOR 240 10-432 PLATE, INHIBITOR 139 10-333 NUT 438 10-253 STUD 437 10-461 F.H.C.S. 236 10-155 PLUG, DRAIN, MAGNETIC 135 10-285 WASHER, SEAL 134 10-399 O-RING 133 10-314 NUT 732 10-279 STUD 131 10-293 WASHER, SPLINED 130 10-296 LOCKNUT, NYLON 129 10-295 WASHER, TAB 128 10-292 THRUST HUB 127 10-017 KEY 126 10-242 COVER, NUT 125 10-203 WASHER, TAB 124 10-639 SEAL 123 10-291 SEAL 122 10-394 BEARING, ROLLER 121 10-364 CARRIER, BEARING 120 10-290 O-RING 119 10-499 WASHER, THRUST 118 10-289 LOAD RING 117 10-509 BEARING 116 10-299 SHIM SET 115 10-269 BEARING 114 10-258 GEAR 113 10-360 SHAFT, PROP, LH 112 10-400 O-RING 111 10-397 SLEEVE, ALIGNMENT 110 10-261 PINION 19 10-358 WASHER, BELLEVILLE 18 10-260 LOCKNUT, STAKE 17 10-557 SPACER, LOWER HSG 16 10-377 PINION BEARING 15 10-288 SET, SHIM 24 10-526 WASHER, TONGUED 13 10-259 BEARING 12 10-200 SHAFT, VERTICAL, BOTTOM 11 10-245 520 LOWER HOUSING 1


520 Lower Gear Housing Assembly (Left Hand) Figure 4-1

Start to rebuild the lower gear housing (10-245) by first inspecting the casting for any damage or defects. Next, thoroughly clear any sediment, metal shavings or debris that may be adhered to internal surfaces or hidden in pockets or cavities, as demonstrated in figure 4-1. Best results can be achieved by using compressed air and a dry rag.



Onto vertical gear shaft (10-200), slide over bearing (10-259) so that it is orientated as shown in figure 4-2. Once bearing has been installed, place tongued washer (10-526) over top of gear shaft as demonstrated in drawing 4-1 below. Drawing 4-1

Figure 4-3

At top of shaft, fasten on first half of lock nut (10-573)*. See figure 4-3.

* First nut of assembly is placed with chamfered corners face down as shown in drawing 4-2. Drawing 4-2


520 Lower Gear Housing Assembly (Left Hand) Figure 4-4 Figure 4-5 Figure 4-6

To begin assembly, place .020 in (.51 mm) shims (10-288) and bearing race (10-377) into seat at bottom of housing as shown in figure 4-4 through 4-6. Lubricate race with 90w oil for ease of installation. Refer to diagram 4-1 for correct tools and orientation required to install bearing race. Tools required for this procedure are bearing driver (TO-021) and bearing driver assembly (TO-022). Diagram 4-1

AB

CD

EFG

A: Nut (TO-022) B: Locating Disk

(TO-022) C: Casting (10-245) D: Drive Screw

(TO-022) E: Shims (10-288) F: Bearing Race

(10-377) G: Bearing Driver

(TO-021) Place tools as seen in diagram and turn nut clockwise to pull bearing driver into housing to properly seat bearing race.



As shown in figure 4-7, lubricate the upper bearing race (10-259) with 90w oil and then drive into seat as shown. Use bearing driver (TO-017) and impact rod (TO-037) to ensure that race is installed correctly. Refer to figure 4-8 for correct installation of race.

Figure 4-8



Through top of gear housing, insert upper bearing and vertical gear shaft assembly so splines and threads are visible as shown in figures 4-9 and 4-10 below. Figure 4-10

Figure 4-11

While holding shaft in place, rotate gear housing to install lower bearing (10-377) to vertical gear shaft. Splines and threads will show when bearing is pushed on correctly. Refer to figure 4-11 and drawing 4-3 for assistance. Drawing 4-3



Figure 4-12

! CAUTION This procedure may not be the final time that the lock nut is fastened to the vertical shaft. Pprocedures may require that shim adjustments be performed to thisvertical shaft’s bearing sets. If adjustments are required, then the nut will need to be removThis lock nut has been designed to be applied safely only ONE TIME, and should never be reused for operation of the drive.

ost

ed.

It is required that the assembler obtain two lock nuts to rebuild this part of the stern drive. Use one lock nut for all adjustments and the other for final installation once all adjustments have been performed.

Figure 4-13 As shown in figure 4-12, slide pinion gear (10-261) on to splines at bottom of vertical shaft. Secure gear to shaft with washer (10-358) and lock nut (10-260). After all adjustments have been made, at the final installation, apply *Loctite 271 or equivalent to threads of lock nut.

New Used

New lock nut will still retain its oval thread hole, while used nut will have been rounded

after being applied once.



Double checking that the first part of upper lock nut system has been fastened down hand tight, proceed by placing spline socket (TO-034) over splines as shown in figure 4-14. Over end of spline suse an appropriwrench to turn shaftfasten lock nut (10-260) atbottom to 150 lb-ft (203 Nm) as shown i

ocket, ate torque

and

n

igure 4-15

figure 4-15.

F



Once lock nut has been secured to shaft, proceed by measuring rolling torque with gauge as demonstrated in figure 4-16. Rolling torque measurements should range from 10-12 lb-in (1.13-1.36 Nm) when properly set. To adjust rolling torque, set tools up as shown in figure 4-17. Use socket wrench (TO-033) over nut and spline socket (TO-034) to tighten or loosen the nut to adjust rolling torque.

Figure 4-17



Through bottom opening of gear housing, insert gauge (GO-015) to check gap of pinion gear. Refer to figure 4-18 for assistance in set up of measurement. Using a feeler gauge as shown in figure 4-19, check gap of pinion gear.

Figure 4-19

Ideal gap should range from .024-.026 in (.61-.66 mm). If gap needs to be increased, then decrease the amount of shims that are at the bearing race. If gap nto be decreased, then shims are added. When making these adjustments, the pinion gear and nut will have to be removed in order to access the bearing race. Be sure to reassemble all parts as described in directions that accompany figures 4-12 through figures 4-18. When rebuilding a drive unit, try to use the exact amount and size of shims that were taken out. This will minimize the amount of adjustments that may need to be made and reduce the

eeds

number of times that the ring race is removed and replaced.


520 Lower Gear Housing Assembly (Left Hand) Diagram 5-2 The diagram below illustrates the order of parts that are assembled over the next few steps. The drawing is intended to serve as a general idea for the order in which the parts are to be assembled and should not be substituted for assembly procedures described in this section.

A: Bearing Race (10-394) B: Bearing (10-509) C: Propeller Shaft (10-360) D: Gear (10-258) E: Bearing (10-269)

A B C D E



Press bearing (10-269) onto gear (10-258). Lubricate mating surfaces w90w oil before pressing the two (2) components together. Refer to figur4-20 for

ith

e visual description of assembly.

! CAUTION

inner surface

When assembling gear and beari g

e

ncluster, always press components together using the inside ring of thbearing. Never apply force to any other surfaces as damage may result to rollers or retainer on bearing. Use an electric or hydraulic press to combine components if available.

Figure 4-21 Into the nose cone, place .020 in (.51 mm) shim

and

(10-299) in front of bearing race (10-269). Use impact rod (TO-037), alignment plate (TO-036)bearing driver (TO-025) to correctly install bearing race into nose cone.

Bearing Race

Shim



Place gear and bearing previously assembled into bearing race at the front of the nose bore. This setup is required for the installation of a counter rotating propeller shaft (10-360). Refer to figure 4-22 for visual description of component. Gear and lock nut on vertical shaft will need to be removed in order to properly assemble all components of lower gear housing.

Figure 4-23

Over the splines at the end of the shaft, replace lower pinion gear (10-261). Secure shaft with washer (10-358) and lock nut (10-260). Note: There are several shim adjustments that may be required to properly reassemble this drive variation. Use old lock nut when making these adjustments. When all settings are correct, remove old lock nut and replace with new one using *Loctite 271 or equivalent for added safety. Tighten nut down to 150 lb-ft (204 Nm).


520 Lower Gear Housing Assembly (Left Hand) Figure 4-24 Figure 4-25

Obtain counter rotating propeller shaft (10-360) and install components as instructed. As shown in figure 4-24, take propeller shaft and press on bearing (10-509) until seated firmly against ridge at center. Next, press needle bearing race (10-394) over end of propeller shaft so that the two (2) holes are aligned as demonstrated in figure 4-25. Drawing 4-4

Needle Bearing

Oil Passage WayPropeller Shaft

Oil Passage Hole

Bearing Race

! CAUTIONTo prevent damage and minimize wear, keep holes aligned when installing bearing race. This alignment will ensure that proper oil flow through shaft and bearings is created when shaft is in motion, as shown in drawing 4-4. Do not press race beyond ridge of shaft. Severe risk of metal fatigue and flying debris may result from part shattering.



Install propeller shaft assembly into lower gear housing as shown in figure 4-26.

Figure 4-27

Notice: The next few procedures will demonstrate acomplete overhaul of the lower bearing carrier. If bearings and races in carrier are suitable for reuthen only follow procedure for replacement of seals

se, .

ever reuse carrier seals if grease and water Nseals have been exposed to more than two hundred (200) hours of operation.



Figure 4-28

Obtain lower bearing carrier

igure 4-29

Using bearing driver (TO-019), to

it

(10-364) and inspect for damage before continuing assembly.

F

install needle bearing (10-394) incarrier as shown in figures 4-29 through 4-31 and drawing 4-4. Lubricate bearing on all surfaceswith 90w gear oil before installinginto the carrier.


520 Lower Gear Housing Assembly (Left Hand) Drawing 4-4 Figure 4-30

Figure 4-31



Install left hand rotation prop shaft’s bearing race (10-509) into carrier

using bearing driver (TO-017) as shown in figure 4-32.

Figure 4-33

Proper installation will have the taper of the bearing race facing outward as shown in figure 4-33.



Using seal driver (TO-030), press seal #1 (10-291) and seal #2 (10-639) into bearing carrier as shown in figure 4-34. To install correctly, slide on two (2) seals at opposite ends of the seal driver. Verify that seals oppose one another while resting on seal driver and that rubber gaskets rest against circular ridge before installing into carrier. Around outside surface of each seal, apply thin layer of * Loctite 271 or equivalent to lock seal in place. Refer to diagram 4-4 for assistance in installation of seals into the bearing carrier.

Diagram 4-4

Step #1 Step #2

Seal Driver

Carrier

Press in seal #1 and flip tool over to install seal #2

TO-030

10-63910-291


520 Lower Gear Housing Assembly (Left Hand) Figure 4-35 Figure 4-36

Once seals are in place, apply grease to them and slide carrier over propeller shaft as seen in figure 4-35. Place tab washer (10-295) on top of carrier as shown in figure 4-36. Next, apply oil to cover nut (10-242) threads, then fasten into lower gear housing as shown in figure 4-37. Tighten cover nut into lower gear housing using cover nut wrench (TO-029). Tighten nut until all movement (back and forth) of the propeller shaft is eliminated. Figure 4-37 Figure 4-38



Place indicator rod (GO-016) onto top of vertical drive shaft to verify backlash of gears. Set dial indicator (GO-017) perpendicular to indicator rod. Set probe tip of dial indicator on mark (II) of the indicator rod as shown in figure 4-43. Verify that propeller shaft (10-360) is secure from movement by tightening cover nut until no shaft rotation occurs. Place hand at top of vertical shaft and turn back and forth lightly to feel gear mesh. Find where gears touch and set indicator. Next, turn shaft slowly until gears come in contact with each other again. The amount of movement that occurs between gear contact is the gap spacing or backlash.

Spacing should be .011-.013 in (.28-.33 mm) . when properly set. If adjustments are required, shimming will need to be performed at the nose cone bearing race. Refer to figure 4-21.

Figure 4-40

To make adjustments, disassemble lower drive unit, using Chapter 5 for assistance. Remove bearing race and adjust with appropriate shims, (more shimming will decrease backlash, less shimming will increase backlash) then replace all removed components and recheck backlash. Note: Several adjustments to the shims may need to be made in order to properly set the backlash of the gears. A trial and error approach may need to be performed before the proper backlash can be achieved.



When backlash of gears has been properly set, remove cover nut and bearing carrier from lower housing. When removed, proceed by inserting load ring (10-289) into opening at bottom of lower housing as demonstrated in figure 4-41. Note: Only install load ring for final assembly. Only install load ring after all other adjustments are made, and never reuse ring once it been installed.

has

Figure 4-42

With load ring in place, proceed by placing thrust ring (10-499) into gear housing as shown figure 4-42. Note: Install thrust ring so that tapered end is facing down in the lower housing.



Apply grease between seals (10-291 and 10-639) and grease o-ring (10-290), then place in housing as shown in figure 4-43.

! CAUTION Drive unit may suffer serious damage if o-ring is omitted from installation. Always be sure that o-ring is properly placed before operating stern drive.

Figure 4-44

hen load ring, thrust ring, and

own

ote: Make sure that key way is

Wo-ring are in place, proceed by installing bearing carrier assembly into housing as shin figure 4-44. Naligned before continuing to next step.



Using pliers or appropriate tool, insert key (10-017) into key way as shown in figure 4-45.

Figure 4-46

With key in key way, place tab washer (10-295) onto bearing carrier so that tabs are aligned in their respective slots as seen in figure 4-46. For easier assembly in the following steps, bend all square tabs up thirty degrees (30o) before installing cover nut.


520 Lower Gear Housing Assembly (Left Hand) Figure 4-47 Figure 4-48 Figure 4-49

If cover nut (10-242) is aluminum, apply anti-seize compound to threads before fastening into lower gear housing. If cover nut (10-242) is brass, lubricate with 90w oil before fastening into lower gear housing. Tighten cover nut into lower gear housing as shown in figure 4-47, using cover nut wrench (TO-029) as shown in figure 4-48. Tighten nut until shaft has rolling torque ranging between 25-30 lb-in (2.82-3.39 Nm) as demonstrated in figure 4-49. While tightening cover nut, periodically check rolling torque measurement, using spline socket (TO-034) and a rolling torque wrench, being sure not to exceed the maximum setting of 30 lb-in (3.39 Nm). When rolling torque has been adjusted to the correct setting, proceed by bending a tab into an aligning slot on the cover nut, as demonstrated in figure 4-50. Never loosen nut to align tabs, as load ring will not expand to fill the gap created when nut is backed off. After one (1) tab is bent into slot, bend the other three (3) tabs down. Figure 4-50 Drawing 4-7

Turn retainer nut until tab is aligned,thenpry up to lockposition.



Proceed by removing first half of lock nut (10-573) by using socket wrench (#TO-033), and then bearing from shaft (10-200). When these parts have been removed, insert spacer tube (10-557) onto vertical gear shaft. With spacer installed, replace bearing over shaft and fasten down with first half of lock nut. Tighten nut down to 150 lb-ft (203 Nm). After nut has been tmeasure rolling torque on shaft as shown in figure 4-49, on the previous page. Rolling torque should range between 25-30 lb-in (2.82-3.39 Nm) when properly set. If adjustments to torque are required, then remove the upper bearing race and add shims to increasthe rolling torque resistance.

ightened,

e

Drawing 4-8

Note: This spacer does not exist in all 520 stern drive models made prior to 1999. It has been introduced as a product improvement and is suggested that it be included in older models when being rebuilt.



Next, fasten second half of lock nut (10-574) down so that the two (2) surfaces come in contact. Once surfaces come in contact as shown in figure 4-52, back nut off until holes are aligned. When holes are aligned, turn nut off 2/6 or two (2) holes counter clockwise. Next, fasten two (2) halves together using the six (6) set screws (10-578) that are part of the assembly. Tighten each screw to 75 lb-in (8.47 Nm) using a star pattern to fasten nuts together as demonstrated in diagram 4-5. Use *Loctite 271 or equivalent on set screws and nut when fastening final assembly together.

Diagram 4-5 Figure 4-53

1

234

5

6



Install alignment sleeve (10-397) then o-ring (10-399) and o-ring (10-400) as shown in figure 4-54.

Figure 4-55

At nose of bullet on lower gear housing, install washer/gasket (10-285) and magnetic drain plug (10-155) until snug in housing.



Disassembly of 520 Lower Gear Housing

Chapter 5

Disassembly of 520

Lower Gear Housing


Disassembly of 520 Lower Gear Housing Figure 5-1

At top of vertical gear shaft (10-200), remove six (6) set screws (10-578) from lock nut assembly as shown in figure 5-1.

Figure 5-2

Next, pry down tab as shown in figure 5-2 and remove cover nut (10-242) from bottom of lower gear housing. An extension bar may be needed for leverage on the cover nut wrench (TO-029) in order to free cover nut. Refer to figure 5-3. Figure 5-3



Once cover nut has been removed, proceed by removing tab washer (10-295) from top of bearing carrier as shown in figure 5-4. With tab washer removed, insert slide hammer (TO-028) into slot of carrier as shown in figure 5-5. Alternate back and forth until carrier is extracted.

Figure 5-5



After removing bearing carrier, reach in housing and pull out o-ring (10-290) as shown in figure 5-6. Next, remove thrust washer (10-499) and load ring (crush ring) (10-289) as shown in figure 5-7. Do not reuse load ring.

Figure 5-7



Next, remove propeller shaft by slightly turning back and forth until it is free from housing as shown in figure 5-8.

Figure 5-9

When propeller shaft is free, remove lock nut from face of gear on vertical shaft as shown in figures 5-9 and 5-10. Figure 5-10



Once lock nut has been removed, gear and bearing will slide off end of shaft as shown in figure 5-11.

Figure 5-12

When gear and bearing are clear, pull out vertical shaft from gear housing as shown in figure 5-12.



Once these major components are removed, the gear housing is able to be rebuilt as shown in figure 5-13. If bearings require removal and replacement, then start at the upper bearing race and work down through gear housing. Note whatever shims are removed from races so that they can be accurately replaced upon reassembly. To remove bearing races, special tools will be required. These tools can be found in Chapter 2, the Tools and Gauge section of this manual. The removal of components on the shaft will require blocks and a press. Gear and bearing separation will require the use of special tooling also, described in the Tools and Gauge section of this manual, Chapter 2.

Figure 5-14

500 Series Upper Gear Housing Assembly

500 Series Technical Manual 6 - 1 March 2010

Chapter 6

500 Series Upper Gear

Housing Assembly



! Notice

To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a Konrad 500 Series stern drive, it is suggested that all reassembly be done using the same shim set-up as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled. * Note: Loctite 271 or equivalent requires 24 hours to cure.

30-207

GEAR CHART520

OVERALLGEAR RATIO

UPPER GEARSET NUMBER

540/560OVERALL

GEAR RATIO

1.30:1

1.43:1

1.57:1

1.79:1

1.97:1

1.09:1

1.21:1

1.33:1

1.51:1

1.67:1

30-203

30-208

30-211

30-482

.020

Konrad

DRAWING NUMBER30-006M

30-006MDRAWING NO.

1:3

6/27/06DATE:

TITLE:

TOLERANCE

MAT'L:

DRIVESHAFT HOUSING ASS'Y

.010

DRAWN BY: LH

.XX

SCALE:

.005

APP.BY:

.XXX

.X

5

6

6

36

38

35

39

41

34

19

20

33 37

7

2

3

15

14

16

17

18

28

1

3215

14

21

8

10

31

3022

23

25

4024

13

12

13

10

9

29

26

27

11

4

5

41 10-373 CROSS & BEARING 240 10-280 WASHER, HARD 139 10-518 RING, SNAP 838 10-493 O-RING 137 10-305 GASKET 136 10-494 PIN, ENGAGEMENT 135 10-365 SHAFT, END YOKE 134 10-366 H-YOKE 133 10-306 O-RING 132 10-094 PLUG 131 10-395 S.H.C.S. 230 10-376 S.H.C.S. SS 229 10-110 S.H.C.S. 628 10-505 COUPLING 127 10-303 O-RING 126 10-209 COVER, TOP 125 30-325 NUT, LOCKING 124 10-300 WASHER, TAB 123 10-298 O-RING 122 10-210 REAR COVER 121 10-246 SLEEVE 120 10-307 SEAL 119 10-367 SHAFT, END YOKE 118 10-578 S.H.C.S. 617 10-577 NUT, LOCKING 116 10-576 NUT, LOCKING 115 10-304 SHIM SET 214 10-267 BEARING 213 10-299 SHIM SET 212 10-556 SPACER 111 10-201 SHAFT, VERTICAL, TOP 110 10-269 BEARING 29 PINION, VERTICAL 18 GEAR, HORIZONTAL 17 10-374 KIT, SPRING 16 10-010 PLUG, DRAIN 25 10-285 WASHER, SEAL 24 10-487 CABLE, CONTINUITY 13 10-479 SCREW, SELF TAPPING 22 10-368 PLATE, GROUND 11 10-244 HOUSING, DRIVESHAFT 1


Y'SSA TXEN

**

# TES RAEG ROF TRAHC RAEG EVOBA EES *

3

DRIVESHAFTHOUSING ASS’Y

GEAR RATIOUPPER GEAR


1.30:1

APP.BY:DRAWN BY: LH

.005

GEAR RATIO

.020

.XX

1.43:1

1.57:1

ALL RIGHTS RESERVED

OF KONRAD MARINE.

520 OVERALLSET NUMBER

.010

.XXX

THIS DOCUMENT AND THE INFORMATIONCONTAINED HEREIN IS CONFIDENTIALAND PROPRIETARY PROPERTY AND MUSTNOT BE USED, REPRODUCED, OR ITSCONTENT DISCLOSED, IN WHOLE OR IN

540 OVERALL

HD UPPER HOUSING ASSY

3

14

13

15

32

331

28

17

20

7

8

35

31

12

21

22

23

25

16

10

24

12

8

9

24

27

25

18

19

26

30

34

2

3

54

6

11

29

FACTORY TO VERIFY CORRECT COMPONENTS

** THIS ASSY IS STANDARD HD UPPER HOUSING ASSY, IF YOURS IS A CUSTOM ASSYPLEASE CONTACT THE

*SEE ABOVE GEAR CHART FOR GEAR SET #

35 10-280 WASHER, HARD 134 10-305 GASKET 133 10-094 PLUG 132 10-505 COUPLING 131 30-325 NUT 130 10-368 PLATE, GROUND 129 10-110 S.H.C.S. 628 10-209 COVER, TOP 127 10-303 O-RING 126 10-306 O-RING 125 10-287 S.H.C.S. 224 12-550 CAP SCREW 223 12-558 COVER, REAR, HD 122 10-298 O-RING 121 10-300 WASHER, TAB 120 30-571 SET, LOCKNUT 119 12-018 SEAL 118 30-533 U-JOINT ASS'Y, HD 117 12-019 BEARING SET, HD UPPER 116 12-081 SHIM SET, HD UPPER 115 30-202 SET, LOCKNUT 114 10-304 SHIM SET 113 10-267 BEARING 112 10-299 SHIM SET 211 10-556 SPACER 110 10-201 SHAFT, VERTICAL, TOP 19 10-403 GEAR 18 10-269 BEARING 27 10-402 PINION 16 10-374 KIT, SPRING 15 10-010 PLUG, DRAIN 24 10-285 WASHER, SEAL 23 10-479 SCREW 22 10-487 CABLE 11 12-036 UPPER HOUSING, HD DRIVE 1


*

*

ECNARELOT

:ELTIT

:ETAD:THGIEWSBL 60.59 01/80/60

:L'TAM :ELACS

3300--444455MM

ENIRAM DARNOK 4002 THGIRYPOC )C(

802-03

3:1

1:97.11:79.1

GGEEAARR CCHHAARRTT

TNESNOC NETTIRW ROIRP TUOHTIW ,TRAP

112-03702-03284-03

302-031:12.1

1:33.11:15.11:76.1

1:90.1

3300--444455MM.ON GNIWARD

Y'SSA TXEN

REBMUN GNIWARD

darnoKX.

DHTFAHSEVIRD

GNISUOHYSSA



Figure 6-1

Prepare upper gear housing (10-244, Standard or 12-036, HD) by inspecting for damage. Using compressed air or dry rag as shown in figure 6-1, clean all debris and dirt from internal cavities and surfaces.

Figure 6-2

As shown in figure 6-2, fasten ground plate (10-153) and cable assembly (10-487) with self-tapping screw (10-479). Apply grease to the threads of each screw and tighten until snug against housing.



Figure 6-3 As indicated in figure 6-3, install washer/gasket (10-285) and vent screw (10-010) in both locations. Apply grease to each screw and tighten until snug into housing, but take caution not to over tighten. Figure 6-4

Referring to figure 6-4, insert the seven (7) studs (10-313 (6) and 10-279 (1), 520 or 10-279 (7), 540 / 560) into the housing. Use *Loctite 271 or equivalent to secure threads into the housing. Figure 6-5

If old valve assembly is worn or damaged, install new spring kit (10-374) at right of drive shaft entry as shown in figure 6-5.



Figure 6-6

Press bearing (10-269) onto desired gear from table 6-1. Use a light coating of gear oil on mating surfaces to ease compression of components together. Table 6-1 Pinion Gear

Figure 6-7

Press bearing (10-269) onto desired gear from table 6-2. Use a light coating of gear oil on mating surfaces to ease compression of components together. Refer to table 6-2 for desired gear ratio information. Table 6-2 Driven Gear

Overall Gear Ratio

520 540/560

Gear Part Number

1.43:1 1.21:1 10-478 1.57:1 1.33:1 10-402 1.79:1 1.51:1 10-707 1.97:1 1.67:1 12-151

Overall Gear Ratio

520 540/560

Gear Part Number

1.43:1 1.21:1 10-477 1.57:1 1.33:1 10-403 1.79:1 1.51:1 10-708 1.97:1 1.67:1 12-150



Figure 6-8

On to the vertical gear shaft (10-201), press on gear and bearing assembly as shown in figure 6-8. Verify that the correct gear and bearing combinations are installed onto the vertical shaft. Lubricate mating surfaces with a light coating of 90w gear oil to ease installation of components. Figure 6-9 shows assembly complete.

! CAUTION

Apply pressure only to inner ring of bearing when installing components to shaft. Never press against roller bearings

or gear teeth, as severe damage to components can result. Figure 6-9

Figure 6-10

When bearing and gear are completely installed onto shaft, slide on spacer (10-556) as shown in figure 6-10. Spacer has one (1) end with larger opening to accommodate spline run-out near bearing.



Figure 6-11 Initially place .025 in (.64 mm) shims (10-299) in front of bearing race (10-269) into seat at top of housing as shown in figure 6-11. Use bearing driver (TO-025) to drive bearing race securely into housing as shown in figure 6-12. (Apply light coating of gear oil to mating surfaces for easier installation of parts).

! CAUTION Figure 6-12

Note: Always install bearing races using the correct tools to ensure that proper seating of race is achieved. At the bottom of upper gear housing, shown in figure 6-14, place .015 in (.38 mm) shim (10-304) in front of bearing race (10-267) and drive in until firmly seated with bearing driver (TO-031). Figures 6-13 and 6-14 show installation complete.

Figure 6-13 Figure 6-14



Figure 6-15

As shown in figure 6-15, insert shaft assembly through top of housing (oil all bearings before final installation). For ease of installation, rotate housing ninety degrees (90o), as shown in drawing 6-1. When assembly is in place, move to bottom of housing to insert bearing (10-267) over end of vertical shaft as shown in figure 6-16.

Figure 6-16 Drawing 6-1

0

90o

o



Figure 6-17 Figure 6-18

Figure 6-19

When bearing from previous procedure is in place, proceed with assembly by fastening first half of lock nut set. Using locknut (10-576) , apply anti-seize to the bottom of the nut and tighten down to 200 lb-ft (271 Nm) of torque. For best assembly results, use spline socket (TO-034) and socket wrench (TO-033) to perform procedure. Refer to figures 6-17 through 6-20 for pictorial demonstration of procedure.

Figure 6-20



Figure 6-21

After first lock nut has been fastened in place, continue assembly by measuring rolling torque on shaft. If shim thickness was initially correct, then the rolling torque will range between 24-28 lb-in (2.71-3.16 Nm). If rolling torque is not within this range, then adjustments to the shims at the bearing races may need to be performed. To adjust rolling torque of the shaft, add or remove appropriate shims in front of the lower bearing race. If shims are added, then the rolling torque will increase, whereas removing shims will then decrease rolling torque.

Figure 6-22

When correct rolling torque setting has been applied to the shaft, proceed by verifying the gap spacing of the gear on the vertical shaft. Insert gauge (GO-013) into opening at back of housing. Using feeler gauge, probe hole to measure gap spacing of gear. Spacing should range between .024-.026 in (.61-.66 mm) when properly set. To adjust gap spacing, add or remove shims as needed to the upper bearing race. When performing this adjustment, remember that whatever is done to the top will need to be done equally at the bottom. This means that if shims are added at the top race, then the same amount of shims must then be removed from the bottom race. This adding and subtraction of shims thus ensures that the overall distance between bearings will stay constant. This consistency will keep rolling torque from changing when adjusting of the gear height is necessary. See following page for more in depth information about this assembly.



Diagram 6-1

A: Vertical Shaft (10-201) B: Gear (variable) C: Bearing and Race (10-269) D: Shims (10-299) E: Spacer (10-556) F: Shims (10-304) G: Bearing and Race (10-267) H: Lock Nut Set (30-202) Diagram 6-1 shows a drawing of the assembly of the vertical gear shaft when completely installed. When making adjustments to rolling torque and gear gap, it is important to understand how shims affect the settings. Refer to arrow F: At this location shims are either increased or decreased to adjust the rolling torque of the shaft. Refer to arrow D: At this location shims are either increased or decreased, depending on whether the gear height needs to be raised or lowered. Note: When setting the shaft for proper rolling torque, it is advised that location F shim adjustments be completed first. Once rolling torque settings are correct, move to location D (the upper bearing race) and adjust shims to set gear height. When adjusting the top to set gear height, remember to make the appropriate adjustments at the opposite race (location F) to counter whatever effects were created by shimming the gear. This careful balance will ensure that the rolling torque setting will not change when making gear height adjustments.

AB

C

D

E

FG

H

Cut-Away View of Vertical GearShaft Assembly



Drawing 6-2

When all rolling torque and gear height adjustments have been made, secure shaft with second nut of lock nut system. Follow the directions in drawing 6-2 for additional instructions. Tighten first nut down to 200 lb-ft (271 Nm) of torque. When first nut is in place, follow directions at left (Drawing 6-2) for placing second nut onto shaft. On second nut, apply *Loctite 271, or equivalent, to threads and back off as indicated.

Figure 6-23

When fastening with set screws, be sure to apply *Loctite 271, or equivalent, to threads before fastening down each screw to 75 lb-in (8.47 Nm) of torque. New set screws are recommended. When lock nut system has been installed, measure rolling torque once again. The installation of the second nut should have reduced the rolling torque measurement to range between 15-20 lb-in (1.69-2.26 Nm).

Tighten two nuts together until touching,then back off second nut until holes lineup..

Turn second nut off 1/6 turn

Turn second nut offanother 1/6 turn, for atotal 2/6 of a re volution

A lign holes and fas ten s ix set sc rewsto join and pull two nuts together.Use Loc tite 271 on all threads of set sc rews and on second nut for final assem bly.



Figure 6-24

As shown in figure 6-24, place .015 in (.38 mm) shim (10-304, Standard or 12-081, HD) in front of bearing race (10-267, Standard or 12-019, HD) before installing seat at front of housing. Use bearing driver (TO-031, Standard or TO-102, HD) to properly seat bearing into housing. After bearing race has been installed, slide universal drive shaft assembly through opening as shown in figure 6-25.

Figure 6-25

Note: When installing bearing races it is best to use the same amount of shims that were in place before rebuilding of the drive began. This practice will eliminate many adjustments to settings that would occur when starting from scratch. To eliminate having to make several shim adjustments, always follow original factory settings as closely as possible. Shim sizes provided in assembly instructions are given as recommendations when starting from scratch. These sizes are based on averages from all units produced and are not necessarily correct

for every gear housing.



With a standard upper housing (10-244) and shaft in place, slide on bearing (10-267) until firmly seated against race in housing. After installing bearing, oil and slide spacer tube (10-246), followed by aft horizontal gear and bearing set constructed earlier. Be sure to oil all bearings before installation. Refer to figures 6-26 and 6-27 or diagram 6-2 for assembly layout. Figure 6-26 Figure 6-27

Diagram 6-2

A B C D E F

A: Universal shaft (10-367) B: Upper gear housing (10-244) C: Shims (10-304) and Bearing Race (10-267) D: Bearing (10-267) E: Spacer (10-246) F: Gear (variable) and Bearing Assembly (10-269)



Figure 6-28

With a HD upper housing (12-036) and when shaft is in place, slide on bearing (12-019) until firmly seated against race in housing. Figure 6-29 After installing bearing, slide first locknut (12-034) over shaft. Figure 6-30 Slide bar between universal shaft (11-990) to stop rotation while tightening.

Figure 6-31 Tighten locknut against bearing to 100 lb-ft (136 Nm) of torque using spanner wrench (TO-098). Be sure to oil all bearings before installation. Refer to figures 6-28, 6-29, 6-30, & 6-31 or diagram 6-3 for assembly layout.



Diagram 6-3

A: Universal shaft (11-990) F: Gear (variable) and Bearing Assembly (10-269) B: Upper gear housing (12-036) G: Washer (10-280) C: Shims (12-081) H: Double nut set (11-588, 11-589, 11-590 (6)) D: Bearing and bearing race (12-019) E: Double nut set (12-033, 12-034, 10-578 (6)) Slide horizontal gear and bearing set constructed earlier along with bearing race into back of housing over universal shaft until gear is against shoulder of universal shaft. Refer to Figure 6-32 and 6-33. Figure 6-32 Figure 6-33



Diagram 6-4

! CAUTION At this step, shimming may be required if new parts have been installed. When shimming adjustments are completed, always install a new lock nut to minimize the risk of used lock nut failing and drive being severely damaged. Place bar between universal shaft to stop rotation before tightening nut. Fasten washer (10-280) and first lock nut (11-589) onto end of shaft. Tighten nut to 200 lb-ft (271 Nm) of torque using a 13/4” socket. Reference diagram 6-4 and figure 6-34.



Figure 6-35

Place .045 in (1.14 mm) shims (10-299) on top of bearing race as shown in figures 6-35 and 6-36 and insert tab washer (10-300) on top of shims as shown in figure 6-37. Refer to diagram 6-5 for complete assembly. Diagram 6-5

Figure 6-36

Figure 6-37

Top View of Upper Gear Housing

A back cover

B o-ring

C tab washer

D shims

E bearing race



Figure 6-38

Press o-ring (10-298) into groove around opening at the back of the upper housing. Apply grease liberally to o-ring to prevent drying and easier assembly. This operation will also be performed at the top of the housing when installing the top cover plate.

Figure 6-39

Install back cover (10-210, Standard or 12-558, HD) . Use two (2) bolts (10-376, Standard or 10-385, HD) in the top bolt holes, and two (2) bolts (10-395, Standard or 12-550, HD) in the bottom bolt holes. Apply grease to threads of all bolts and tighten down to 20 lb-ft (27 Nm) for Standard or 40 lb-ft (54 Nm) for HD of torque each, as demonstrated in figure 6-39.



Figure 6-40

Measure the rolling torque on the shaft with a torque gauge as demonstrated in figure 6-40. Rolling resistance of torque should range between 25-30 lb-in (2.82-3.39 Nm). If rolling torque is too low, then add shims to the outside of the back bearing race. If rolling torque needs to be decreased, then remove shims from back bearing race. Note: Once adjustments have been made, apply white lithium marking grease to gear teeth. Rotate shafts back and forth to verify that the gear mesh is correct, and that the teeth are contacting down the center.

Figure 6-41 At top, insert gauge (GO-014), and measure gap distance of gear, as shown in figure 6-41. Ideal gap spacing will range between .024-.026 in (.61-.66 mm). If gap spacing is incorrect, then adjust gear position by shimming the bearing race where the universal drive shaft enters the gear housing. To decrease the gap measurement, remove shims at the bearing race. To increase gap measurement, add shims at the bearing race. In order to maintain the proper rolling torque, you must add the same amount of shims to the rear as were removed from the front or remove shims from the rear if shims were added to the front. Note: If shimming adjustments are needed, use bearing driver (TO-031) to punch out bearing race of standard housing and bearing remover (TO-101) to punch out race of HD housing.



Figure 6-42 When rolling torque and gap spacing settings are correct, check the backlash .013-.017 in (.33-.43 mm) and grease the gears to check the gear mesh. Gear mesh pattern should be centrally located on the face of each gear tooth. Disassemble and remove horizontal gear shaft assembly. Proceed by installing front seal (10-307, Standard or 12-018, HD). Apply Permatex or equivalent to the outside of the seal, then firmly tap into opening at top-front of housing (10-244, Standard or 12-036, HD) using driver (TO-031, Standard or TO-100, HD). On inside portion of seal, apply marine grease to rubber gasket. Reference to figure 6-42. Figure 6-43

When seal is in place, replace horizontal shaft assembly. With a standard housing, slide front bearing, spacer tube, and gear and bearing set back onto the universal shaft. Refer to Diagram 6-2 shown earlier. With a HD housing, the front bearing must be secured to the universal shaft with the second nut of the locknut system. Apply *Loctite 271, or equivalent, to the threads of

both locknuts. When fastening together, tighten first locknut (12-034) down to 100 lb-ft (136 Nm) of torque using spanner wrench (TO-098). Refer to Figure 6-43. When first nut is in place, follow directions in Drawing 6-2 for placing second locknut (12-033) onto shaft.



Figure 6-44

When fastening with six set screws (10-578), be sure to apply *Loctite 271, or equivalent, to threads before fastening down each screw to 75 lb-in (8.47 Nm) of torque. New set screws are recommended.

Figure 6-45

For both the standard upper housing and the HD upper housing, install o-ring (10-306), washer (10-280) and clean the threads on the end of shaft. The universal shaft will be secured with the second nut of the locknut system. Apply *Loctite 271 or equivalent to the threads of both locknuts. When fastening together, tighten first locknut (11-589) down to 200 lb-ft (271 Nm) of torque using 1 ¾” socket. Refer to Figure 6-45. When first nut is in place, follow directions in Drawing 6-2 for placing second locknut (11-588) onto shaft.



Figure 6-46

When fastening with six set screws (11-590), be sure to apply *Loctite 271, or equivalent, to threads before fastening down each screw to 75 lb-in (8.47 Nm) of torque. New set screws are recommended. Install shims, tab washer, and o-ring (10-289). Be sure to grease o-ring when installing. Next, install rear cover and tighten to 20 lb-ft (27 Nm). Recheck rolling torque because rolling torque my increase slightly with addition of seal. Do not adjust rolling torque to compensate for this addition.

Figure 6-47

At top of housing, grease and install o-ring (10-303) and cover plate (10-209). Align bolt hole pattern as shown in figure 6-47. Fasten plate down with six (6) bolts (10-110), grease and tighten each to 20 lb-ft (27 Nm) of torque. Notice: At this point, assembly of the upper gear housing is completed.


520/540 Upper Gear Housing Disassembly

Chapter 7

Disassembly of Upper Gear

Housing



! Notice



520/540 Upper Gear Housing Disassembly Figure 7-1

Remove six (6) bolts from top cover as shown in figure 7-1.

Figure 7-2

Pull out o-ring as demonstrated in figure 7-2 and set aside.



Remove four (4) bolts from back cover as demonstrated in figure 7-3.

Figure 7-4

Pull out o-ring as shown in figure 7-4 and set aside in safe place.



At back cover, remove tab washer and shims as demonstrated in figures 7-5 and 7-6. Use a flat head screwdriver or needle nose pliers to lift rings out if stuck on surface of bearing race.

Figure 7-6



For disassembly of the horizontal gear shaft assembly, for both the Standard and HD upper housing, start by sliding bar between universal shaft to stop rotating. At back, remove six (6) set screws that lock two nuts together, as shown in Figure 7-7.

Figure 7-8 As shown in figure 7-8, loosen and remove first lock nut from horizontal shaft using 13/4” socket. Once first nut is removed, use socket and breaker bar to remove second locknut.

Figure 7-9 Next, remove bearing race from seat in housing. Bearing race is free floating and not firmly seated so excessive force is not required to extract from seat. Refer to figure 7-9.



In the Standard upper housing unit, hold onto spacer, gear and bearing, then remove universal drive shaft. Once shaft is clear, pull out spacer, gear and two (2) bearings. Reference figure 7-10 and drawing 7-1.

Drawing 7-1

Pull shaft straight out while holdinggears and spacers in place duringextraction.

Universal driveshaft assembly



In the HD upper housing, after removal of bearing race and gear and bearing combination, remove six (6) set screws that lock two nuts together holding the front bearing of the shaft, as shown in figure 7-11.

Figure 7-12

As shown in figure 7-12, loosen and remove first locknut using spanner wrench (TO-098). Once second nut is removed, use wrench and breaker bar to remove second locknut. While holding onto bearing, remove universal drive shaft. Once shaft is clear, pull out bearing. Reference drawing 7-2.

Drawing 7-2



At front, drive out seal and small bearing race as shown in figures 7-13 and 7-14. When removing bearing race, use a bearing remover (TO-080, Standard or TO-101, HD). These will not damage the surfaces of either bearing race or seal.

Figure 7-14



Figure 7-15 At bottom, remove six (6) screws that lock two (2) nuts together. Then with socket wrench (TO-033), remove the first nut. Once first nut has been removed, use socket wrench, spline socket and breaker bar to loosen second nut. When removing second nut, place arms of socket wrench against two (2) studs on housing. Next, place socket over spline socket and apply force from breaker bar in a clockwise motion to loosen nut as demonstrated. Drawing 7-3

Figure 7-16

Figure 7-17

Loosen six(6) set screws

& remove

Use Konrad socket to loosen nut

Place Konradsocket againststud and turnspline socketwith wrenchclockwiseuntil loose

socket here



Remove lower bearing, then pull gear, bearing and shaft assembly out through the top as shown in figures 7-18 and 7-19. After removing shaft, remove bearing race using bearing remover (TO-080).

Figure 7-19


Transom Assembly

Chapter 8

Transom Assembly


Transom Assembly

! Notice

To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a Series 500 stern drive, it is suggested that all reassembly be done using the same shim set-up as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled.

* Note: Loctite 271 or equivalent requires 24 hours to cure.

.X

.020

.XX1:3

REVISIONDRAWING NO.

NEXT ASS'Y

DR

ALL RIGHTS RESERVED

DATE SYM30-003M

DRAWING NUMBERDO NOT SCALE DRAWING

(C) COPYRIGHT 2004 KONRAD MARINE

.010

MAT'L:

23

19

17

14

13

4

5

26

20

24

22

31

25

21

30

2928

27

1

2

3

78

10

9

11

11

12

18

20

16

15

6

31 10-479 SCREW, SELF TAPPING 130 10-326 TUBE, HOSE CONNECTOR 129 10-324 H.H.C.S. 228 10-221 COVER 127 10-325 BUSHING, RUBBER 126 10-334 NUT, NYLOCK, BRS 825 10-487 CABLE, CONTINUITY 124 10-415 WASHER 823 10-251 STUD 822 10-357 TRANSOM PLATE 121 10-392 FOAM GASKET 120 10-333 NUT, NYLOCK, BRS 419 10-343 FLAT WASHER, S.S. 218 10-468 STUD 217 10-253 STUD 216 10-456 ANODE, GIMBAL ASS'Y 115 11-285 GASKET, ANODE 114 10-331 CONNECTOR 113 10-330 GASKET 112 12-401 SCREW, SELF TAPPING 211 11-171 CABLE, CONTINUITY 210 10-321 COTTER PIN 19 10-215 PIN 18 10-320 H.H.C.S. 27 10-225 PLATE, WIRE 16 10-431 SEAL 15 10-382 PLAIN BEARING 14 10-381 PLAIN BEARING 13 10-409 F.H.C.S. 92 10-406 PLATE, COVER 11 10-240 HOUSING, GIMBAL, 500 SERIES 1


500.

WS :YB NWARD:YB.PPA

:ELACS

GGIIMMBBAALL HHOOUUSSIINNGG AASSSS''YY,, 550000 SSEERRIIEESSXXX.

410-03

3300--000033MM

ECNARELOT

:ELTIT

:ETAD:THGIEWSBL 89.43 30/03/01

darnoKNOITAMROFNI EHT DNA TNEMUCOD SIHT

LAITNEDIFNOC SI NIEREH DENIATNOCTSUM DNA YTREPORP YRATEIRPORP DNA

STI RO ,DECUDORPER ,DESU EB TONNI RO ELOHW NI ,DESOLCSID TNETNOCTNESNOC NETTIRW ROIRP TUOHTIW ,TRAP

.ENIRAM DARNOK FO

GIMBALHOUSING ASS’Y

.005

.XX

.010

.X

WEIGHT:

Konrad

DRAWING NUMBER

NEXT ASS'Y

OF KONRAD MARINE.

30-170 .020

DATE

GIMBAL RING ASS'Y, 500 SERIES

15.06LBS

DRAWING NO. DR

DATE:

REVISION

1:3

11/3/03

SYM

30-004M

30-004M

TITLE:

TOLERANCE

MAT'L:30-014


THIS DOCUMENT AND THE INFORMATIONCONTAINED HEREIN IS CONFIDENTIALAND PROPRIETARY PROPERTY AND MUSTNOT BE USED, REPRODUCED, OR ITSCONTENT DISCLOSED, IN WHOLE OR INPART, WITHOUT PRIOR WRITTEN CONSENT 30-297

23

7

16

19

18

15

6

22

121110

9

7

13

1

14

5

6

2

3

8

1110

9

17

20

21

4

23 11-768 BUSHING, TILLER ARM 122 10-832 O-RING, STEERING PIN 121 10-482 SCREW, BRS 120 10-483 CABLE, CONTINUITY 119 10-352 NUT, HEX, NYLOCK 118 10-216 H.H.C.S. 117 10-220 NUT, JAM, NYLOCK 116 10-834 WASHER, TAB 115 10-231 ARM, STEERING 114 10-217 PLATE, BACKING 113 10-395 S.H.C.S. 212 10-232 SHAFT 111 10-356 SCREW, FILLISTER 410 10-355 WASHER, LOCK, SS 49 10-354 RETAINER 48 10-238 TRIM SENDING UNIT 17 10-226 PIN, HINGE 26 10-222 WASHER 35 10-234 BUSHING 24 10-479 SCREW, SELF TAPPING 13 10-218 GIMBAL SHIM KIT 12 10-371 BEARING 11 11-991 RING, GIMBAL 1


:ELACS:YB.PPA

WS :YB NWARD

XXX.

GIMBALRINGASS’Y

DATE:

Konrad

DRAWING NUMBER

NEXT ASS'Y

DATE

.020

SYM DR

30-005M

30-005M

TITLE:DO NOT SCALE DRAWING

1:2.5

11/4/0310.28LBSWEIGHT:

DRAWING NO. REVISION

TOLERANCE

MAT'L:30-014

BELL HOUSING ASS'Y, 500 SERIES

DRAWN BY: SW

.XXX

SCALE:

.005

.XXAPP.BY:

.010

.X


5

9

9

10

11

12

12

1

4

2

2

3

3

4

8

FASTEN TO GIMBAL RING

6

12 10-479 SCREW, SELF TAPPING 211 10-345 CABLE, CONTINUITY 110 10-341 HOSE 19 10-322 CLAMP, HOSE 28 10-339 NPT CONNECTOR 17 10-370 VALVE ASSY 16 10-336 CLAMP, BELLOWS 25 10-230 BELLOW 14 10-334 NUT, NYLOCK, BRS 63 10-415 WASHER 62 10-250 STUD 61 10-239 HOUSING, BELL, 500 SERIES 1


7

BELLHOUSINGASS’Y


Transom Assembly Figure 8-1

Inspect gimbal housing (10-240), as shown in figure 8-1, for damage before beginning assembly. Using compressed air or a dry rag, remove any sediment or dirt that may be adhered to surfaces or settled in cavities.

! CAUTION A thoroughly cleaned and prepared gimbal housing will ease installation of components and ensure greater reliability during operation.

On outside surface of composite bushing (10-381) apply light coating of *Loctite 271 or equivalent, as shown in figure 8-2, to ensure a secure installation. Next, use bushing driver (TO-059), shown in figure 8-3, to press in composite bushing (10-381) until seated flush with housing. Figure 8-4 demonstrates a properly installed bushing in the gimbal housing. Figure 8-2 Figure 8-3 Figure 8-4



As in the previous step, repeat installation procedure for composite bushing (10-382) into lower bushing seat as seen in figure 8-5. The lower composite bushing is slightly larger than the upper composite bushing and is installed with bushing driver (TO-060). For installation of seal in next assembly step, this composite bushing requires a recessed seating approximately 1/8 inch (3.2 mm) in from bottom surface.

Figure 8-6

Around outside surface of seal (10-431) apply a light coating of *Loctite 271 or equivalent. Using bushing driver (TO-062) drive seal (10-431) into place as shown in figure 8-6 and drawing 8-1. Seal will be flush with housing if composite bushing installed previously was recessed properly in seat. When seal has been properly installed, continue assembly by applying a light coating of marine grade grease to inside rubber ring of seal.

Drawing 8-1



Apply light coating of *Loctite 271 or equivalent around outside surface of composite bushing (10-371). Next, as shown in figure 8-7, drive in composite bushing (10-371) at bottom of gimbal ring (10-236) with bushing driver (TO-062) until flush with surface.

Figure 8-8

As shown in figure 8-8, loosely install backing plate (10-217) using two (2) bolts (10-395). Note: Do not tighten plate at this time, it will be secured in a later step.



At top of gimbal ring, push shaft (10-232), as shown in figure 8-9, through square opening until threads protrude slightly at top. For ease of installation, a light coating of marine grease around shaft surface may be applied.

Figure 8-10

After placement of shaft into gimbal ring, push the end of the shaft on the new assembly through seal and bushing of gimbal housing. Refer to figure 8-10 for assistance with assembly. Shaft should be inserted so that threads are only slightly seen in opening. Placement of steering arm and lock nut require clearance from shaft in next step.



Through tiller arm (10-231), insert bolt (10-216) and fasten with lock nut (10-352), as shown in figure 8-11. Tighten only by hand at this step of assembly.

Through opening at top of gimbal housing, place washer (10-214) over threads of the protruding shaft, previously installed. Next, place tiller arm (10-231), washer (10-460) and nylon lock nut (10-220) on shaft. To secure these components, a gradual insertion of the shaft is required to slowly expose more threads to allow adequate space for fastening lock nut. At this step, hand-tighten lock nut on threads to secure the gimbal ring loosely in place. Refer to figures 8-12, 8-13 and drawing 8-2 for proper assembly. Proceed with next few assembly instructions before rigidly securing lock nut to shaft. Figure 8-12 Drawing 8-2 Figure 8-13

Locknut

Washer

Tiller Arm

Washer

Shaft



In between the gimbal housing and gimbal ring, place a .030 in (.76 mm) shim to set the height of the gimbal ring for later universal drive shaft alignment. Through bottom of gimbal housing, push swivel pin (10-215) through shims, bushing and washer (10-218). Swivel pin has a notch that allows for rotation and alignment with cotter pin hole on gimbal housing. Refer to figure 8-14, 8-15 and drawing 8-3 for assistance with assembly.

Figure 8-15 Drawing 8-3

Gimbal Ring Gimbal Housing

Swivel Pin

Hole

washershims



Through hole on swivel pin (10-215), insert cotter pin (10-321) to hold alignment of gimbal ring with gimbal housing. Refer to figure 8-16. Do not bend cotter pin until measurements and final adjustments have been performed. The next few assembly steps will discuss the procedures for performing gimbal ring height adjustments and measurements.

Figure 8-17

After cotter pin has been inserted, continue assembly by securing shaft at top of gimbal ring with nylon lock nut, as shown in figure 8-17. Shaft and lock nut were loosely installed in figure 8-12, 8-13 and drawing 8-2. Lock nut must be tightened enough to eliminate movement of the gimbal ring in the vertical direction and cause a secure interface between the gimbal ring and housing. A slight resistance to rotation of gimbal ring should be present when shaft has been properly fastened

with nylon lock nut.



Next, install composite fiber bushing (10-234) into the holes on the horizontal axis of the gimbal ring as shown in figure 8-18.

Figure 8-19

A properly installed bushing will look like the one in figure 8-19.



When bushings have been installed, measuring of the gimbal ring height is able to be performed as shown in figures 8-20 and 8-21. Insert bearing carrier and gauge bar into position. In the center hole of the bearing carrier, insert gimbal ring alignment gauge (GO-018), then measure the spacing between the bar and the flat surface with a feeler gauge set. The spacing will range between .080-.090 in (2.03-2.27 mm) when the correct shims at the bottom swivel pin have been installed. Any adjustments to this setting will

require the swivel pin to be removed Figure 8-21 and shims to be added or subtracted

as needed. Loosening of the lock nut on the upper shaft is required to perform these adjustments. After all shim adjustments have been performed, remove nylon lock nut (10-220) and replace it with a new one to ensure proper function during stern drive operation.

! CAUTION Failure to replace lock nut may cause premature wear or loosening while in operation. Notice to Technician: The gimbal carrier assembly instructions are

discussed in Chapter 9 of this manual. In order to perform the procedures mentioned above, a used or rebuilt bearing carrier will need to be placed in the center opening of the gimbal housing. Temporarily secure bearing carrier to housing to perform adjustments and measurements. Using the shaft hole of the bearing carrier to locate gimbal ring alignment gauge, perform measurements using the bearing carrier intended to be used for operation. By using the same bearing carrier the most accurate setup can be achieved for the particular drive system being assembled.


Transom Assembly When all measurements have been performed and adjustments have been made, fasten new nylon lock nut to upper shaft as shown in figure 8-22. Then bend cotter pin at bottom to secure swivel pin in place as demonstrated in figure 8-23. Figure 8-22 Figure 8-23

Once shaft and swivel pin have been secured, tighten backing plate (10-217) using two (2) bolts (10-395). Torque bolts to 40 lb-ft (54 Nm), as shown in figure 8-24. When backing plate has been secured, tighten lock nut on tiller arm to secure arm to shaft as shown in figure 8-25. Figure 8-24 Figure 8-25



Completion of these steps concludes the setup for the gimbal ring to the gimbal housing. The next assembly step details the placement of the trim switches and wire harness assemblies to the transom assembly. These assemblies are located in one (1) of two (2) places depending on the 520/540 model year. The purpose for movement of the harness assembly was to allow for easier access after the aluminum center plug on older models was phased out. Through the opening at the center or top (depending on stern drive model year), pull wires for the starboard and port side trim switches through the back. Starboard wire

leads and port side wire leads each contain one half (1/2) of a conical white rubber bushing. On all surfaces of these bushings, apply Permatex FORM-A-GASKET compound, then press bushing halves into countersink opening at center. Over wires, slide on cover plate (10-225) and seal bushings in hole by securing with bolts (10-320) until snug against housing. Complete switch assembly is listed as part number 10-238.

! CAUTION When installing trim switches, be sure to run starboard switch on right side of gimbal ring and port side switch on left side of gimbal ring. Gimbal housing should be orientated as it would be on stern of boat looking towards the bow. Figure 8-27 Figure 8-28 Figure 8-29



Slide tapered bushing (10-325) onto tube (10-326) so that when the tube is installed the long neck of the tube faces outward towards the bow of the boat as shown in figure 8-30.

Figure 8-31

Next, apply Permatex FORM-A-GASKET to two (2) bolts (10-324) and fasten cover plate (10-225) over tube and tighten as shown in figure 8-31.



Next, push hose (10-341) on tube (10-326) at inside of gimbal housing, then secure hose to tube with clamp (10-322) as shown in figure 8-33.

Figure 8-33

After installation of hose, apply Permatex FORM-A-GASKET adhesive sealer to inner surface of bellows (10-230) and push over opening at center of bell housing (10-239). When bellows has been properly seated over opening, fasten with hose clamp (10-336). Be certain to place hose clamp before seating bellows otherwise removal is imminent. With a long flat bladed screwdriver, fasten clamp until watertight seal is created.

! CAUTION

Over tightening clamp or puncturing bellows may cause water leakage into sealed system and potentially cause a failure with the stern drive. Be certain when installing bellows to transom assembly that there are no defects, tears, or pinches in the rubber.



After securing bellows, apply teflon type thread sealing tape to nipple (10-339) and install into bell housing as shown in figure 8-34. Also fasten ground wire (10-345) to the bell housing as shown with screw (10-479).

Figure 8-35

As shown in figure 8-35, press hose (10-341) attached to tube on gimbal housing to the nipple just installed. Seal rubber hose with clamp (10-322) around brass nipple.



After installing bellows and rubber hose to bell housing, apply coating of Permatex FORM-A-GASKET adhesive to inner surface of bellows (10-230) at opposite end. Press bellows over hole in center of gimbal housing to seal opening, then secure bellows in place with clamp (10-336). Secure bellows with the screw on the clamp at approximately the seven o’clock (7:00) position, to avoid any clearance problems during tightening. Refer to figure 8-36 for proper installation.

Next, place two (2) washers (10-222) over protruding end of bushings (10-234), as shown in drawing 8-4, on the inside of the gimbal ring. Liberally grease washers and bushings, then push bell housing (10-239) down until threaded holes are aligned with bushings as in figure 8-37. Figure 8-37 Drawing 8-4



Into threaded holes on bell housing (10-239), spray a coating of *Loctite primer 7471 or equivalent before fastening hinge pins in place. Additionally, apply *Loctite 271 or equivalent to hinge pins (10-226) before fastening to bell housing as shown in figure 8-38.

Figure 8-39

Figure 8-39 shows how to properly torque the hinge pins using 60 lb-ft (81 Nm) of torque.



As shown in figure 8-40, install starboard and port side switch assembly (10-238) over tops of hinge pins on gimbal ring.

! CAUTION When installing trim switches over hinge pins, make sure to place them in correct locations with regards to port and starboard sides of the boat. Also wires should be routed outside of gimbal ring.

Figure 8-41

Fasten down switch assemblies with two (2) screws (10-356), washers (10-355) and retainers (10-354) using threaded holes on gimbal ring as shown in figure 8-41. Grease screws before tightening snug into position.



Using connector block (10-331), fasten black and gray oil hoses to center as shown in figure 8-42. To outside of connector, fasten four (4) braided oil hoses (10-412) or (11-078), depending on the year of stern drive production.

Figure 8-43

Apply *Loctite 271 or equivalent to threads of two (2) studs (10-468), then fasten to connector (10-331) until snug as shown in figure 8-43.



At bottom of transom assembly, apply *Loctite 271 or equivalent to two (2) studs (10-468) and fasten into threaded holes as shown in figure 8-44. Next, place gasket (10-330) over studs and start to install connector block by pushing gray and black hoses through opening.

Figure 8-45

Fasten connector and hoses to studs using washers (10-343) and lock nuts (10-333) as shown in figure 8-45. When connector assembly has been secured to transom assembly, place gasket over studs as shown in figure 8-45, before proceeding with mounting of sacrificial anode in next assembly step.



Over studs of connector, place anode (10-456) and fasten with lock nuts (10-333) until snug as seen in figure 8-46.

Figure 8-47

At bottom of housing, connect continuity cable assembly (10-483) to gimbal ring and gimbal housing as shown in figure 8-47. Use two (2) screws (10-479) with light coating of marine grease on threads to connect wire.



At bottom of transom assembly connect ground wire cable (10-345) from bell housing to gimbal housing as shown in figure 8-48. Use two (2) self tapping screws (10-479) with light coating of marine grease on threads to connect wire. Note: This wire is connected from the inside of the bell housing.

Figure 8-49

As shown in figure 8-49, attach back cover plate (10-406) to transom using nine (9) screws (10-409). Apply a bead of silicone to back outer edge of plate before fastening in place to ensure water tight seal.



If not previously installed, fastening of six (6) studs (10-250) may be required around perimeter of bell housing as shown in figure 8-50. Before fastening studs into threaded holes, apply *Loctite 271 or equivalent to threads and then tighten until snug. Note: The studs in this bell housing are for a standard application. Some assemblies may have different studs.

Figure 8-51

As shown in figure 8-51, install oil check valve (10-370) into hole on bell housing. Make sure that when installing the check valve, the shoulder of the valve is kept flush with the bell housing.



When rebuilding transom assembly, it is suggested that a new foam gasket (10-392) be installed. Using contact cement, available at hardware stores, measure and cut gasket (if necessary), then cement and press gasket into groove around backside of the transom assembly. Refer to figure 8-52 for assistance.

Figure 8-53

Finally, into opening at back of transom, insert upper bearing carrier assembly and fasten with three (3) bolts (10-385). Torque bolts to 70 lb-ft (95 Nm). When installing transom assembly to the transom plate (10-357) make sure that all oil hoses and seals were properly installed and connected. Refer to figure 8-53. Since various setup applications exist for different vessels, several variations of couplers and flanges may be used to connect the bearing carrier and drive train.

Gimbal Housing Bearing Carrier Assembly

Chapter 9

Gimbal Housing Bearing Carrier

Assembly



! Notice

To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a Konrad stern drive, it is suggested that all reassembly be done using the same shim set-up as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled. * Note: Loctite 271 or equivalent requires 24 hours to cure.


DATE:WEIGHT:9.26 LBS.

TITLE:

TOLERANCE

MAT'L:

30-018M

ASS'Y, GIMBAL CARRIER, 520/540, TRILOBE FLANGE

SCALE:

5/7/03

1:2

DRAWING NO.30-018M

.XX

DRAWING NUMBER

KonradPART, WITHOUT PRIOR WRITTEN CONSENTOF KONRAD MARINE.

CONTENT DISCLOSED, IN WHOLE OR IN

.020

NEXT ASS'Y

.X

.010

NOT BE USED, REPRODUCED, OR ITS

.005

DRAWN BY: SMJAPP.BY:

THIS DOCUMENT AND THE INFORMATIONCONTAINED HEREIN IS CONFIDENTIALAND PROPRIETARY PROPERTY AND MUST

.XXX

10

11

13

2

14 THIS CARRIER ASSEMBLY IS USEDFOR TRI-LOBE APPLICATIONS

3

OIL SUPPLY

AT 30

CARRIERS WITHIN TRANSOM ASSEMBLIES PRIOR TO 7/28/04 OR BEFORE A TRANSOM ASSEMBLY SERIAL #3084 SHOULD USE SEAL #11-612.

4

9 7

2. ITEM #3-IF GIMBAL FLANGE IS REPLACED ON ORIGINAL GIMBAL

62

5

1

* NOTES: 1. ITEM #14-ORIGINAL GIMBAL CARRIERS WITHIN TRANSOM ASSEMBLIES PRIOR TO 7/28/04 OR BEFORE A TRANSOM ASSEMBLY SERIAL #3084 WILL USE SEAL #10-472. ALL OTHER GIMBAL CARRIER ASSEMBLIES SHOULD USE SEAL #11-612.

12

8

14 11-612 SEAL 113 10-470 NIPPLE 112 10-469 PLUG 311 10-396 PLUG 210 10-385 S.H.C.S. 39 10-383 O-RING 18 10-485 PLUG 17 10-473 SEAL 16 10-389 LOCKNUT 15 10-568 KIT, SHIM 14 10-558 SPACER 13 10-466 FLANGE, GIMBAL 12 10-471 BEARING 21 10-467 CARRIER, GIMBAL 1


DDOO NNOOTT SSCCAALLEE DDRRAAWWIINNGG

GIMBALCARRIERASS’Y

2 14

3

AT 30

USE THIS ASSEMBLY FOR DRIVE SHAFT INSTALLATIONS

GIMBAL CARRIER ASSEMBLY.

8

9

OIL SUPPLY

PLEASE CONTACT FACTORY TO VERIFY CORRECT COMPONENTS.

IF YOURS IS A CUSTOM ASSEMBLY17

6 2

5

4

11

10

THIS IS A STANDARD 520/540

12

13 14 11-612 SEAL 113 10-396 PLUG 212 10-385 S.H.C.S. 311 10-469 PLUG 310 10-470 NIPPLE 19 10-383 O-RING 18 10-485 PLUG 17 10-473 SEAL 16 30-324 NUT, LOCKING 15 10-568 KIT, SHIM 14 10-558 SPACER 13 10-629 FLANGE, CARRIER 12 10-471 BEARING 21 10-467 CARRIER, GIMBAL 1


.010

NOT BE USED, REPRODUCED, OR ITS

DRAWN BY: SMJ

10.060 LBS.

APP.BY:SCALE:THIS DOCUMENT AND THE INFORMATION

CONTAINED HEREIN IS CONFIDENTIALAND PROPRIETARY PROPERTY AND MUST

.XXX


* NOTES: 1. ITEM #8-ORIGINAL GIMBAL CARRIERS WITHIN TRANSOM ASSEMBLIES

PRIOR TO 7/28/04 OR BEFORE A TRANSOM ASSEMBLY SERIAL #3084 WILL USE SEAL #10-472. ALL OTHER GIMBAL CARRIER ASSEMBLIES SHOULD USE SEAL #11-612.

2. ITEM #9-IF GIMBAL FLANGE IS REPLACED ON ORIGINAL GIMBAL

CARRIERS WITHIN TRANSOM ASSEMBLIES PRIOR TO 7/28/04 OR BEFORE A TRANSOM ASSEMBLY SERIAL #3084 SHOULD USE SEAL #11-612.

:ETAD:THGIEW30/7/5

ECNARELOT

:ELTIT

500.

:L'TAM

3300--004444MMAASSSS''YY,, GGIIMMBBAALL CCAARRRRIIEERR,, 552200//554400,, 44 BBOOLLTT FFLLAANNGGEE

2:1

.ON GNIWARD 3300--004444MM

.ENIRAM DARNOK FO

NI RO ELOHW NI ,DESOLCSID TNETNOCTNESNOC NETTIRW ROIRP TUOHTIW ,TRAP

darnoKX.

Y'SSA TXEN

020.

XX.

REBMUN GNIWARD


.020

Konrad

ASSY, HEAVY DUTY GIMBAL CARRIER, 500 SERIES, TRILOBE FLANGE

TOLERANCE

DRAWING NO. DATE

TITLE:

SCALE:MAT'L:

ALL RIGHTS RESERVED

SYM

DATE:WEIGHT:9.54 LBS. 4/5/05

1:2



.XX .010

.005

DRAWN BY: SCAPP.BY:

.XXX

REVISION


1410

7

AT 30°

OIL SUPPLY

5

14 13

8

32 1

9

4

12

6

11

14 10-471 BEARING 213 10-466 FLANGE, GIMBLE 1

10-578 S.H.C.S. 6 11-586 NUT, LOCKING 1 11-585 NUT, LOCKING 1

12 30-324 NUT, LOCKING 111 11-612 SEAL 110 10-485 PLUG, EXPANSION 19 10-470 NIPPLE 18 10-469 PLUG 37 10-396 PLUG SHSS 26 10-385 S.H.C.S. 35 10-383 O-RING 14 10-473 SEAL 13 10-568 KIT, SHIM 12 10-558 SPACER 11 10-467 CARRIER, GIMBAL 1


RD3300--330011MM

Y'SSA TXEN

REBMUN GNIWARD3300--330011MM

X.


.020

.XXALL RIGHTS RESERVED

DRAWING NO. DATE SYM REVISION DR

10.33 LBS.


DRAWING NUMBER

Konrad(C) COPYRIGHT 2004 KONRAD MARINE

30-303M

4/5/05

1:2

NEXT ASS'Y

.X

.010

.XXX

.005

DRAWN BY: SCAPP.BY:

SCALE:

ASSY, GIMBAL CARRIER HEAVY DUTY, 500 SERIES, 4 BOLT FLANGE

30-303M

MAT'L:

TOLERANCE

TITLE:

DATE:WEIGHT:


13 14 10

7

5

4

12 13

8

32 1

9

6

OIL SUPPLY

AT 30°

14 10-629 FLANGE, CARRIER 113 10-471 BEARING 2

10-578 S.H.C.S. 6 11-586 NUT, LOCKING 1 11-585 NUT, LOCKING 1

12 30-324 NUT, LOCKING 111 11-612 SEAL 110 10-485 PLUG, EXPANSION 19 10-470 NIPPLE 18 10-469 BRASS PLUG 37 10-396 PLUG SHSS 26 10-385 S.H.C.S. 35 10-383 O-RING 14 10-473 SEAL 13 10-568 KIT, SHIM 12 10-558 SPACER 11 10-467 CARRIER, GIMBAL 1


11

GIMBAL CARRIERASS’Y

Gimbal Housing Bearing Carrier Assembly Figure 9-1

Prepare bearing carrier (10-467) for assembly by inspecting for damage, burrs or defects that may be present if part has been used. Thoroughly clean carrier using compressed air or with clean dry rag.

Figure 9-2

Install two (2) oil plugs (10-396) in the holes that are one hundred eighty degrees (180o) from each other, and three (3) plugs (10-469) in the holes on the face of the carrier. Install nipple (10-470) into the hole that is at forty degrees (40o). Use teflon tape on threads to prevent leaks.



Put grease on expansion plug (10-485) and press into flange shaft (10-629). Press plug in until it is flush with the shaft. Note:Some applications use flange shaft (10-466).

Figure 9-4

Using bearing driver (TO-057), install bearing race (10-471) into carrier until firmly seated as shown in figure 9-4. Use a light coating of gear oil on outer surface of bearing race to ease installation. Note: The first time through, the installation is completed without seals.



Turn carrier over and install the other bearing race as you did the first one. Refer to figure 9-5.

Figure 9-6

Oil the bearing, insert into carrier and press shaft onto bearing as shown in figure 9-6. Lubricate shaft with oil to help ease installation.



Install spacer (10-558) and then shims (10-568) as shown in figure 9-7. If this is a new assembly, start with .015 in (.13 mm) of shim.

Figure 9-8

Place bearing into carrier then press flange shaft through, using bearing race driver (TO-070), as shown in figure 9-8, until threaded end protrudes through opposite opening of carrier.



Once flange has been properly installed, rotate carrier so that threaders are accessible. Fasten down shaft components with a used locknut (10-389, original*) using a 23/8” socket or a new locknut (11-585, current*) using spanner wrench (TO-079). Torque either locknut to 200 lb-ft (271 Nm), as demonstrated in figure 9-9.

* The original carrier assemblies (30-018 and 30-044) were constructed until 7/28/04. After this date, the current, heavy duty, carrier assemblies (30-301 and 30-303) were implemented. See prints at the beginning of this section for more details. Figure 9-10

In a double nut carrier application, fasten down shaft components with the locknut that has 6 threaded holes (11-585) to 200 lb-ft (271 Nm) torque using a spanner socket (TO-079), as demonstrated in figure 9-10.



After installation of locknut, check rolling torque of components using an appropriate torque gauge, as shown in figure 9-11. Ideal settings will range between 10-15 lb-in (1.13-1.69 Nm) of rolling torque when shim settings are correct. If torque reading is too low, remove shim. If torque is too high, add shim. Note: .001” (.025 mm) of shim will change settings approximately 5 lb-in (.56 Nm). Note: Do not proceed with assembly, beyond this point, if correct settings have not been achieved.

Figure 9-12

When rolling torque settings have been correctly set, continue assembly by removing flange shaft from carrier, as shown in figure 9-12.



Once shaft has been removed from carrier, press remaining bearing off the shaft, as shown in figure 9-13

Figure 9-14

With shaft removed, install bearing and press seal (11-612, current*) into opening, as illustrated in figure 9-14. Apply coating of *Loctite 271, or equivalent, to outer surface of seal to help secure in place after installation. Apply light coating of marine grease to rubber part of seal before pushing shaft through in next step. *If this is an original gimbal carrier prior to 7/28/04 and/or the gimbal flange has a seal diameter of 2.125”, use seal (10-472). If the gimbal carrier was received after 7/28/04 and/or the gimbal flange has a seal diameter of 2.250”, use seal (11-612).

* See notes on assembly prints (30-018 and 30-044) for when seal change occurred.



When seal has been properly seated (seal is level with housing face), push shaft through until it is fully seated against seal and protruding through opposite side as demonstrated in figure 9-15.

Figure 9-16

As previously shown in figure 9-7, reinstall spacer and shims that were used to get the proper rolling torque. This is demonstrated in figure 9-16.



Once bearing and shims are installed, press bearing onto shaft, as shown in figure 9-17. Be sure to oil bearing and shaft prior to installation.

Figure 9-18

In the original carrier assemblies (30-018 and 30-044), install a new locknut (10-389) with *Loctite 271 or equivalent and torque to 200 lb-ft (271 Nm) using 23/8” socket, as demonstrated in figure 9-18.



In the current or heavy duty carrier assemblies (30-301 and 30-303), reinstall locknut (11-585) with *Loctite 271, or equivalent, and torque to 200 lb-ft (271 Nm) using spanner wrench (TO-079), as demonstrated in figure 9-18.

Drawing 9-1

Tighten two nuts together until touching,then back off second nut until holes lineup..

Turn second nut off 1/6 turn

Turn second nut offanother 1/6 turn, for atotal 2/6 of a re volution

A lign holes and fas ten s ix set sc rewsto join and pull two nuts together.Use Loc tite 271 on all threads of set sc rews and on second nut for final assem bly.

After first nut has been installed in heavy duty carrier assembly, follow directions at left for placing second locknut (11-586) onto shaft. On second nut, apply *Loctite 271, or equivalent, to threads and back off as indicated in drawing 9-1.



When fastening with six (6) set screws (10-578), be sure to apply *Loctite, or equivalent, to threads before fastening down each screw to 75 lb-in (8.47 Nm) of torque. New set screws are recommended.

Figure 9-21

In a double nut application, install locknut with 6 thread holes (11-585) with *Loctite 271 or equivalent and torque to 200 lb-ft (271 Nm) with spanner socket (TO-079), as demonstrated in figure 9-19.



Install locknut with 6 counter bored holes (11-586) with *Loctite 271 or equivalent and tighten finger tight until both nuts meet, as shown in figure 9-20. Turn back top locknut until counter bored holes meet with threaded holes. Then turn back two more counter bored/threaded hole positions.

Figure 9-23

Install 6 socket head cap screws (10-578) with *Loctite 271 or equivalent and torque to 75 lb-in. (8.5 Nm), as demonstrated in figure 9-21.



Figure 9-24

With shaft inserted, apply light coating of grease to rubber part of seal (10-473) and *Loctite 271 or equivalent to the outside of the seal. Press on seal as shown in figure 9-22. Shaft should protrude from end of seal.

Figure 9-25

Install o-ring (10-383) and slide down to the base of the carrier, as shown in figure 9-23.



Trim Pump Assembly

Chapter 10

Trim Pump Assembly


Trim Pump Assembly

! Notice

To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a Model 520 stern drive, it is suggested that all reassembly be done using the same shim set-up as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled.

TRIM ASS'Y

DRAWING NO.

48.49 LBS 1/26/98 30-002MALL RIGHTS RESERVED

WEIGHT:

TITLE:

TOLERANCE

MAT'L:

30-002M

1:4SCALE:

APP.BY:DRAWN BY: JW

.XXX

NEXT ASS'Y

SYM

.005

DATE DRREVISION

DATE:DO NOT SCALE DRAWING


.010

.X

6

2

3

1

2

3

3

5 6

9

DOWN HYDRAULIC LINE

UP HYDRAULIC LINE

SETUP REFER TO KM#30-186

8

7

6

53

4

32

102

1

210

23

43

UP PORT

5

5

NOT INCLUDED IN ASS'Y

3

6

DOWN PORT

NOTE: THIS IS THE NEW CURRENT SETUPAS OF JANUARY 1ST, 2009. FOR THE OLD

**

10 12-535 SPACER, ANCHOR PIN 29 11-078 HOSE, BRAIDED, TRIM 48 10-489 HOSE, OIL, GRAY 17 10-490 HOSE, OIL, BLACK 16 10-314 NUT, BRS 45 10-444 WASHER 44 30-024 TRIM CYLINDER ASS'Y 23 10-443 BUSHING, ANCHOR PIN 82 10-442 WASHER 61 10-458 PIN, ANCHOR 2


020.

darnoK

REBMUN GNIWARD

XX.

NOITAMROFNI EHT DNA TNEMUCOD SIHTLAITNEDIFNOC SI NIEREH DENIATNOC

TSUM DNA YTREPORP YRATEIRPORP DNASTI RO ,DECUDORPER ,DESU EB TONNI RO ELOHW NI ,DESOLCSID TNETNOCTNESNOC NETTIRW ROIRP TUOHTIW ,TRAP

.ENIRAM DARNOK FO

TRIM ASS’Y

TRIM ASS'Y, 520/540

SCALE:APP.BY:

30-186M

DRAWN BY: JW

.005


DRAWING NO.

1:4

.XXX1/26/98

DRAWING NUMBER

TITLE:

TOLERANCENEXT ASS'Y

WEIGHT:

.020

Konrad

DATE:

MAT'L:

DRREVISIONSYMDATE



.010

.X

30-186M


23

1

23

3

56

1010

9

65

34

32

7

23

4

3

5

6

1010

65

3

8

10 11-078 HOSE, BRAIDED 49 11-180 HOSE, OIL 18 11-170 HOSE, OIL 17 10-459 PIN, ANCHOR 16 10-314 NUT 45 10-444 WASHER 44 30-024 TRIM CYLINDER ASS'Y 23 10-443 BUSHING, ANCHOR PIN 82 10-442 WASHER 41 10-458 PIN, ANCHOR 1


NOTE: THIS IS THE TRIM CYLINDER ASS'Y BEFORE JAN 1ST 2009

Y'SSA NI DEDULCNI TON

TRIM ASS’Y520/540


Trim Pump Assembly Figure 10-1 Figure 10-2

Install the two (2) solenoid switches (10-691, 24 Volt) or (10-528, 12 Volt), as demonstrated in figure 10-1, onto the trim pump bracket (11-048) by using four (4) HHCS, 1/4”-20 x 1/2”, SS (10-537) and four (4) lock washers, 1/4”, SS (10-984). The solenoids should be fastened so that the smaller studs are facing outward as shown in figure 10-2. Figure 10-3 Figure 10-4

Mount the trim pump & reservoir (10-690, 24 Volt) or (10-430, 12 Volt) with reservoir cover (10-689) as shown in figure 10-3, to the trim pump bracket, from the backside using two (2) HHCS, 3/8”- 16 x 5/8”, SS (10-864) and two (2) lock washers, 3/8”, SS (10-865) as shown in figure 10-4.

10-689



Attach the solenoid link (11-073) as shown in figure 10-5, between the inward studs of each solenoid switch using the hardware supplied, two (2) nuts and two (2) lock washers, with the solenoid switches. Refer to figure 10-6. Figure 10-7 Figure 10-8

Mount the ground bolt HHCS, 5/16”- 18 x 1-1/4”, SS (11-074) to the trim pump bracket with a lock washer, 5/16”, SS (10-538) on either side, followed by a nut 5/16”- 18, SS (10-539) as shown in figure 10-7. One more lock washer and nut will be added to the ground bolt at a later time to fasten the ground wires. The order, in which the hardware is assembled, is shown in figure 10-8.

11-073

11-074


Trim Pump Assembly Figure 10-9

Jump the negative side of the solenoid switch coils together using ground wire (10-536). Jump the negative side of the “up” solenoid switch (solenoid closest to the pump reservoir) to the ground bolt using ground wire (10-535). Hook up the blue and the green wire from the trim pump to the outside stud of the “up” and “down” solenoid respectively. Use the hardware (nuts and lock washers) provided with the solenoid switches. Hook up the black wire from the trim pump to the ground bolt. At this point, the assembly would have a part number of 30-150 (24 Volt) or 30-233 (12 Volt). Figure 10-10 Figure 10-11

Mount the top bracket (11-049) onto trim pump bracket using three (3) HHCS, #10 – 24 x 3/8”, SS (10-815) and three (3) lock washers, #10, SS (10-870) as shown in figure 10-10. Next, insert two (2) 1/2” grommets (11-063) into the holes in the top bracket. Refer to figure 10-11.

10-536

10-535

BlackGreen

Blue

11-04911-063



Figures 10-12 and 10-13 show the terminal strips which will be mounted in the next step. The “position” numbers of the individual terminals are labeled as “pos” and will be referenced when the wires are connected. Figure 10-14

Mount the six (6) position terminal strip (11-069) and the four (4) position terminal strip (11-070) onto the top bracket using four (4) PPHMS, #6 – 32 x 1/2”, SS (11-080) and four (4) lock washer, #6, SS (11-081) each, as shown in figure 10-14.

Pos 1

Pos 2

Pos 3

Pos 4

Pos 5

Pos 6

Pos 1Pos 2

Pos 3

Pos 4


Trim Pump Assembly

Figure 10-15 Insert the change-over relay (11-071, 24 Volt) or (11-212, 12 Volt) into the change-over relay harness (11-072). Mount the relay and harness on the top bracket using one (1) PPHMS, #10 – 24 x 3/8”, SS (11-079) and one (1) lock washer, #10, SS (10-870) as shown in figure 10-15. Connect the individual wires to the terminal strips according to table 10-1 as shown below.

Table 10-1

Wire Number

Wire Color

Wire Length

ROUTE / DESCRIPTION

1 Blue 7-1/8” From pin 85 of relay harness (11-072) to position #6 of 6 terminal strip (11-069)

2 Purple 4-1/2” From pin 30 of relay harness (11-072) to position #1 of 4 position terminal strip (11-070)

3 Black 4-1/8” From pin 86 of relay harness (11-072) to position #2 of 4 position terminal strip (11-070)

4 White 4-1/16” From pin 87 of relay harness (11-072) to position #3 of 4 position terminal strip (11-070)

5 Orange 3-7/8” From pin 87A of relay harness (11-072) to position #4 of 4 position terminal strip (11-070)

11-071 or 11-212

11-072

12345



Figures 10-16 and 10-17 show the eight (8) pin female wire harness (11-061). Install the wire harness to the trim pump assembly. Attach the wires according to table 10-2, as shown on the following page. Figure 10-18 shows the wire harness installed.

Figure 10-17

Figure 10-18

6 79

10

1211

13

14

8

1617

15


Trim Pump Assembly Table 10-2

Wire Number

Wire Color

Wire Length ROUTE / DESCRIPTION

6 Black 14-3/4” From position #1 of 6 position terminal strip (11-069) to ground bolt (11-074)

7 Red 9-7/8” From position #7 of 8 pin female molded plug (11-061) to position #2 of 6 position terminal strip (11-069)


9 Gray 10-1/2” From position #3 of 8 pin female molded plug (11-061) to position #4 of 6 position terminal strip (11-069)

10 Purple 10-5/8” From position #4 of 8 pin female molded plug (11-061) to position #5 of 6 position terminal strip (11-069)

11 Purple 1-1/8” From position #5 of 6 position terminal (11-069) to position #1 of 4 position terminal strip (11-070)


13 White 11-1/8” From position #1 of 8 pin female molded plug (11-061) to position #3 of 4 position terminal strip (11-070)

14 Orange 11-1/8” From position #2 of 8 pin female molded plug (11-061) to position #4 of 4 position terminal strip (11-070)

15 Black 18” From position #8 of 8 pin female molded plug (11-061) to ground bolt (11-074)

16 Blue 16-1/16” From position #6 of 8 pin female molded plug (11-061) to positive side of “up” solenoid coil

17 Green 14” From position #5 of 8 pin female molded plug (11-061) to positive side of “down” solenoid coil



Figure 10-19 shows the cover plate (11-050). This cover plate should be mounted to the top bracket using three (3) HHCS, #10 - 24 x 3/8”, SS (10-815) and three (3) lock washers, #10, SS (10-870). This cover plate is shown mounted in figure 10-20.

Figure 10-20

At this point the trim pump assembly is complete and has a part number of 30-054 (24 Volt) or 30-200 (12 Volt).


Trim Pump Assembly

Trim System Electrical Drawing (12 Volt)


Trim Pump Assembly

Trim System Electrical Drawing (24 Volt)


Trim Pump Assembly Trim System Electrical Drawing for Navy RIBs (24 Volt)


Trim Gauge Assembly Figure 10-21 Figure 10-22 Figure 10-23

Figure 10-21 shows the trim control plate (11-035). Mount the red LED (11-066, 24 Volt) or (11-210, 12 Volt) onto the trim control plate through the hole labeled “LIFT” as shown in figure 10-22. Mount the green LED (11-067, 24 Volt) or (11-211, 12 Volt) as shown in figure 10-23 onto the trim control plate in the hole labeled “TRIM”. Use the hardware provided with the LEDs. Install the two (2) momentary toggle switches (11-065) as shown in figure 10-24 onto the trim control plate, using the hardware provided with the switches. The mounted switches can be seen in figure 10-25. Figure 10-24 Figure 10-25


Trim Gauge Assembly Figure 10-26 Figure 10-27

Mount a second red LED (11-066, 24 Volt) or (11-210, 12 Volt) as shown in figure 10-26 onto the trim control plate in the small hole labeled “LOW DRIVE OIL”. Use the hardware provided with the LED. Figure 10-27 shows this LED mounted. Figure 10-28 Figure 10-29

Mount the trim gauge (11-068) using the u-shaped bracket and hardware provided with the gauge. Figure 10-28 shows a 12 Volt style trim gauge which has light bulb (11-213). Figure 10-29 shows a 24 Volt style trim gauge which has light bulb (10-859). The 24 Volt style also has a voltage reducer (10-949) and additional hardware: PPHMS #4 – 40 x 3/8”, SS (10-907), lock washer #4, SS (10-909) and nut #4, SS (10-908).



Figure 10-30 shows a 24 Volt style trim gauge mounted. Figure 10-31 shows a 12 Volt style trim gauge mounted. Figure 10-32 shows the wire harness (11-064), and figure 10-33 shows the pin configuration of the molded plug (male end). Figure 10-32 Figure 10-33

Figure 10-34

Figure 10-34 shows wires 10-861 and 10-862 which are covered with spiral wrap (10-863). Wire the assembly according to figure 10-35 and table 10-3 (24 Volt) or figure 10-36 and table 10-4 (12 Volt), as shown in the following pages.


Trim Gauge Assembly Figure 10-35 24 VOLT WIRING FOR TRIM GAUGE

Figure 10-36 12 VOLT WIRING FOR TRIM GAUGE


Trim Gauge Assembly The trim gauge 24 Volt assembly can be wired using table 10-3 and figure 10-35. Table 10-3 WIRING DIRECTIONS FOR 24 VOLT

Wire Number

Wire Color

Wire Length

ROUTE / DESCRIPTION

1 Black 12” From position #8 of 8 pin male molded plug (11-064) to ground screw “G” on gauge (11-068)

2 Red 12” From position #7 of 8 pin male molded plug (11-064) to sender screw “S” on gauge (11-068)

3 Gray 12” From position #3 of 8 pin male molded plug (11-064) to extra screw/hardware on voltage reducer plate

4 Purple 12” From position #4 of 8 pin male molded plug (11-064) to input screw on voltage reducer (10-949)

5 White 12” From position #1 of 8 pin male molded plug (11-064) to center screw (common) of “LIFT” toggle switch (11-065)

6 Green 12” From position #5 of 8 pin male molded plug (11-064) to upper screw (down) of “TRIM” toggle switch (11-065)

7 Orange 12” From position #2 of 8 pin male molded plug (11-064) to center screw (common) of “TRIM” toggle switch (11-065)

8 Blue 12” From position #6 of 8 pin male molded plug (11-064) to lower screw (up) of “LIFT” toggle switch (11-065)

9 Green 5-1/16” From upper screw (down) of “TRIM” toggle switch (11-065) to upper screw (down) of “LIFT” toggle switch (11-065)

10 Blue 5-1/16” From lower screw (up) of “TRIM” toggle switch (11-065) to lower screw (up) of “LIFT” toggle switch (11-065)

11 Black 5-5/8” From negative side of “TRIM” LED (11-067) to ground screw “G” on gauge (11-068)

12 Red 5-5/8” From positive side of “TRIM” LED (11-067) to center screw (common) of “TRIM” toggle switch (11-065)

13 Black 5-5/8” From negative side of “LIFT” LED (11-066) to ground screw “G” on gauge (11-068)

14 Red 5-5/8” From positive side of “LIFT” LED (11-066) to center screw (common) of “LIFT” toggle switch (11-065)

15 Black 5-5/8” From negative side of “LOW DRIVE OIL” LED (11-066) to extra screw/hardware on voltage reducer plate

16 Red 5-5/8” From positive side of “LOW DRIVE OIL” LED (11-066) to input screw on voltage reducer (10-949)

17 Blue 21-1/2” From positive side of gauge light bulb (10-859) to panel illumination circuit (external) in boat

18 Purple 19-1/2” From input screw on voltage reducer (10-949) to positive 24 Volts (external) in boat


Trim Gauge Assembly The trim gauge 12 Volt assembly can be wired using table 10-4 and figure 10-36. Table 10-4 WIRING DIRECTIONS FOR 12 VOLT

Wire Number

Wire Color

Wire Length

ROUTE / DESCRIPTION

1 Black 12” From position #8 of 8 pin male molded plug (11-064) to ground screw “G” on gauge (11-068)

2 Red 12” From position #7 of 8 pin male molded plug (11-064) to sender screw “S” on gauge (11-068)

3 Gray 12” From position #3 of 8 pin male molded plug (11-064) to end screw (opposite end of “S”) of the voltage reducer plate

4 Purple 12” From position #4 of 8 pin male molded plug (11-064) to input screw “I” on gauge (11-068)

5 White 12” From position #1 of 8 pin male molded plug (11-064) to center screw (common) of “LIFT” toggle switch (11-065)

6 Green 12” From position #5 of 8 pin male molded plug (11-064) to upper screw (down) of “TRIM” toggle switch (11-065)

7 Orange 12” From position #2 of 8 pin male molded plug (11-064) to center screw (common) of “TRIM” toggle switch (11-065)

8 Blue 12” From position #6 of 8 pin male molded plug (11-064) to lower screw (up) of “LIFT” toggle switch (11-065)

9 Green 5-1/16” From upper screw (down) of “TRIM” toggle switch (11-065) to upper screw (down) of “LIFT” toggle switch (11-065)

10 Blue 5-1/16” From lower screw (up) of “TRIM” toggle switch (11-065) to lower screw (up) of “LIFT” toggle switch (11-065)

11 Black 5-5/8” From negative side of “TRIM” LED (11-211 to ground screw “G” on gauge (11-068)

12 Red 5-5/8” From positive side of “TRIM” LED (11-211) to center screw (common) of “TRIM” toggle switch (11-065)

13 Black 5-5/8” From negative side of “LIFT” LED (11-210) to ground screw “G” on gauge (11-068)

14 Red 5-5/8” From positive side of “LIFT” LED (11-210) to center screw (common) of “LIFT” toggle switch (11-065)

15 Black 5-5/8” From negative side of “LOW DRIVE OIL” LED (11-210) to end screw (opposite end of “S”) of the voltage reducer plate

16 Red 5-5/8” From positive side of “LOW DRIVE OIL” LED (11-210) to input screw “I” on gauge (11-068)

17 Blue 21-1/2” From positive side of gauge light bulb (11-213) to panel illumination circuit (external) in boat

18 Purple 19-1/2” From input screw “I” on gauge (11-068) to positive 12 Volts (external) in boat



Figure 10-37 and 10-38 shows the rear views of completed gauge assemblies (30-180, 24 Volt) and (30-199, 12 Volt). Figure 10-39 and 10-40 shows the front views of completed gauge assemblies (30-180, 24 Volt) and (30-199, 12 Volt). Figure 10-39 Figure 10-40


Chapter 11

540 Lower Gear Housing

Assembly (Left Hand)



! Notice

To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a Model 540 stern drive, it is suggested that all reassembly be done using the same shim amounts as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled. * Note: Loctite 271 or equivalent requires 24 hours to cure.


DRAWN BY: ALBKonrad

.X

CONTENT DISCLOSED, IN WHOLE OR INNOT BE USED, REPRODUCED, OR ITS

DR

47.54 LBS 8/30/04


30-052MDRAWING NO.

.010

1:2


PART, WITHOUT PRIOR WRITTEN CONSENT

.020

.XX

DRAWING NUMBERALL RIGHTS RESERVED

OF KONRAD MARINE.

*SOLD AS GEAR SET 30-206

.005

SCALE:APP.BY:

23

24

22

27

21

25

26

20

32

34

33

32

36

35

11

10

9

38

8

2

6

3

7

4

5

37

31

1

39

30

1213

14

15

40

33

28

29

17

18

19

16

41

41 12-587 PLUG, EXPANSION 140 10-457 WASHER 639 11-549 S.H.C.S. 138 10-653 RACE, BEARING 137 10-613 NUT, RETAINING 136 10-399 O-RING 135 10-400 O-RING 134 10-669 PLUG, EXPANSION 133 10-314 NUT 732 10-279 STUD 731 10-107 S.H.C.S. 130 11-254 ANODE 129 10-155 PLUG, DRAIN, MAGNETIC 128 10-285 WASHER, SEAL 127 10-449 O-RING 126 10-678 CARRIER, SEAL 125 10-607 NUT, COVER, 540 124 10-679 SEAL, OIL 123 11-204 SET SCREW, SHCS, SS 222 11-518 OIL SEAL, FISHLINE CUTTER 121 10-668 WASHER, TAB 120 10-606 CARRIER, BEARING, L.H. 119 10-043 O-RING 118 10-605 WASHER, DISTANCE 117 10-654 RING, LOAD 116 10-660 BEARING SET 115 10-677 SHAFT, PROP, 540, L.H. 114 10-598 GEAR 113 10-657 BEARING SET 112 10-288 SET, SHIM 111 10-260 LOCKNUT, STAKE 110 10-656 WASHER 19 10-597 PINION 18 10-659 BEARING ROLLER 17 10-685 SET, SHIM 16 10-609 SET, SHIM 15 10-649 NUT, NYLOCK 14 10-658 SET, BEARING 13 10-651 BEARING 12 10-595 SHAFT, DRIVE 11 10-600 HOUSING, GEAR, 540 1


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540 GEAR HOUSINGL.H. ASS’Y


Start to rebuild the lower gear housing (10-600, Standard or 12-037, X-Factor) by first inspecting the casting for any damage or defects. Refer to figure 11-1. Next, thoroughly clear any sediment, metal shavings or debris that may be adhered to internal surfaces or hidden in pockets or cavities. Best results can be achieved by using compressed air and a dry rag.

Figure 11-2

Obtain plug (10-669). Glaze the outer diameter of it with *Loctite or equivalent and place in housing. Press in plug until 9


10-66
properly seated as shown in figure 11-2.
11 - 3 March 2009


TO-041 Grease bearing (10-659) and place the bearing onto bearing driver (TO-041). Note: Do not discard cardboard from bearing.

Figure 11-4

Notice in Figures 11-3 and 11-4, the bearing numbers on bearing (10-659) are facing upward. The driver will not work if this step is missed.



Insert bearing (10-659) and bearing driver (TO-041) into the bottom of the housing (with the bearing numbers facing upward).

TO-035

Pull bearing into place using bearing puller (TO-035) and 15/16 wrench as shown in figure 11-5. Note: After bearing is installed, grease cardboard and insert it into bearing to hold needles.

Figure 11-6

Press bearing race (10-653) onto shaft (10-595, Standard or 12-038, X-Factor), as shown in figure 11-6.

10-595 Standard 12-038 X-Factor

10-653



Install bearing set (10-651) and bearing set (10-658) onto shaft (10-595, Standard or 12-038, X-Factor) as shown in figure 11-7.


10-658

10-651

Figure 11-8

Loctite threads and screw locknut (10-649) onto shaft (10-595, Standard or 12-038, X-Factor) and torque to 150 lb-ft (203 Nm) using 1¾” socket, as shown in figure 11-8.


10-649



Place .020 in (.51 mm) shim (10-609) into housing as shown in figure 11-9.

Figure 11-10

Pound race (10-651) into the housing using impact rod (TO-037) and bearing driver (TO-040). This is demonstrated in figure 11-10.



Install the assembled shaft (10-595, Standard or 12-038, X-Factor) into the housing as shown in figure 11-11. Note: Remove cardboard from bearing (10-659) before installing shaft.

Figure 11-12

Place race (10-658) into the housing as seen in figure 11-12.



TO-054

10-613

Oil nut (10-613) and screw into casting using spanner socket (TO-054). Refer to figure 11-13.

Figure 11-14

Tighten nut until shaft has 8-12 lb-in (.90-1.36 Nm) of rolling torque as shown in figure 11-14.



On vertical shaft, install gear (10-597), washer (10-656) and nut (reuse old crimp nut or 3⁄4 - 16 jam nut). Torque nut to 150 lb-ft (203 Nm). Assembly is shown in figure 11-15.

Old Crimp nut or ¾-16 jam nut

10-656

10-597

Note: New locknut (10-260) will be used in final assembly.

Figure 11-16

Check for .024-.026 in (.61-.66 mm) gear height in 3 different places using gage (GO-020). This can be seen in figure 11-17. Note: If gear height is incorrect, remove shaft and install proper shimming. If gear height is correct, continue to the next step. Remove vertical shaft assembly after shimming is correct.



Install .020 in (.51 mm) shim (10-288) into nose cone shown in figure 11-17.

Figure 11-18

Pound race (10-657) into the nose cone using bearing driver (TO-017), impact rod (TO-037) and alignment tool (TO-053) as shown in figure 11-18.

TO-053

TO-017

TO-037



Press bearing (10-657) onto gear (10-598), as shown in figure 11-19, and install into nose cone.

TO-037

Figure 11-20

Reinstall vertical shaft assembly as shown in previous figures 11-11, 11-12, 11-13, 11-14, 11-15. Torque the nut (reuse old crimp nut, or 3⁄4 - 16 jam nut) to 150 lb-ft (203 Nm). This is shown in figure 11-20.



Install bearing (10-660) onto propeller shaft (10-677, Standard or 12-157, X-Factor) as demonstrated in figure 11-21.

Figure 11-22

Install propeller shaft (10-677, Standard or 12-157, X-Factor) into housing (10-600 Standard, 12-037, X-Factor) as shown in figure 11-22.



Press race (10-660) into bearing carrier (10-606) using bearing driver (TO-017) and bearing driver (TO-042) as shown in figure 11-24.

Figure 11-24

Install bearing carrier (10-606) into housing (10-600, Standard or 12-037, X-Factor) as shown in figure 11-24.



Bend outside tab of tab w(10-668) downward 30

asher o as

shown in Figure 11-25.

Figure 11-26

Install retaining washer (10-668) into housing (10-600, Standard or 12-037, X-Factor). This is shown in figure 11-26.



Oil cover nut (10-607) and screw into the casting, as shown in figure 11-27.

10-607

Figure 11-28

Tighten nut with cover nut wrench (TO-052), as shown in Figure 11-28, until propeller shaft cannot move.



Place hand at top of vertical shaft and turn back and forth lightly to feel gear mesh. The amount of movement that occurs between gear contact is the gap spacing or backlash. Spacing should be .011-.013 in (.28-.33 mm) when properly set. If adjustments are required, shimming will need to be performed at the nose cone bearing race.

GO-016 GO-017

Note: Put dial indicator (017) on center mark II of gauge (GO-016) to check backlash.

GO-

-cker

h

Figure 11-30

To check backlash on the XFactor, use backlash che(TO-105) to extend far enougto use gauge (GO-016), as shown in Figure 11-30.



After correct shimming and ve

or final assembly, add .065 -

ote: Add shims to decrease

fter rolling torque is set,

al

d

einstall propeller shaft 0-).

Figure 11-31

backlash is determined, remocover nut, carrier and prop shaft. F.070 in (1.65 – 1.78 mm) shims (10-685) to the race (10-658). Then retighten the nut (10-613) to 150 lb-ft (203 Nm). Check to see if rolling torque is between8-12 lb-in (.90-1.36 Nm) as shown in figure 11-31. Nrolling torque rating. Remove shims to increase rolling torque.

Figure 11-32

Areinstall shaft assembly andreplace used gear nut with finlocknut (10-260). Loctite antorque to 150 lb-ft (203 Nm) as shown in Figure 11-32. R (1677, Standard or 12-157, X-Factor



igure 11-33

stall load ring (10-654) into

igure 11-34

stall washer (10-605) into

F

Inhousing (10-600, Standard or 12-037, X-Factor). This is shown in figure 11-33.

F

Inhousing (10-600, Standard or 12-037, X-Factor) as shown in figure 11-34.



Grease and install o-ring (10-043) as shown in figure 11-35.

Figure 11-36

Install bearing carrier (10-606) into housing (10-600, Standard or 12-037, X-Factor) ashown in figure 11-36.

s

Note: Make sure the notch on the bearing carrier and housing are aligned.



Install tab washer (10-668) into housing (10-600, Standard or 12-037, X-Factor). This is shown in figure 11-37.

Figure 11-38

Apply anti seize and reinstall cover nut (10-607) into housing (10-600, Standard or 12-037, X-Factor) using spanner socket

10-607

(TO-052) as shown in Figure 11-38. Tighten cover nut (10-607) until the rolling torque on shaft (10-595, Standard or 12-038, X-Factor) is 20-25 lb-in (2.26-2.82 Nm).



Next, turn up at least one tab from the retaining washer (10-668), as shown in figure 11-39.

Figure 11-40

Press seal (11-518) into the seal carrier (10-678) with numbers on seal facing downward as it is pressed in, using seal driver (TO-043) as shown in figure 11-40.

11-518



2nd 10-679

Press a second seal (10-679) into the seal carrier (10-678) with cup facing upward as it is pressed in, using seal driver (TO-043).

Figure 11-42

Grease threads and place

10-449

o-ring (10-449) over the seal carrier (10-678) as shown in figure 11-42. Note: Also be sure to pack seals with grease.



Install seal carrier (10-678) onto propeller shaft (10-677, Standard or 12-157, X-Factor) using socket spanner

10-678

11-204

(TO-051). Finally, grease SHCS (11-204) and install into seal carrier (10-678) as demonstrated in figure 11-43.



Chapter 12


Assembly (Right Hand)



! Notice

To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a Model 540 stern drive, it is suggested that all reassembly be done using the same shim amounts as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled. * Note: Loctite 271 or equivalent requires 24 hours to cure.


DATE:


30-047MDRAWING NO. REVISION


Konrad.X

NEXT ASS'Y

DR


DRAWING NUMBER .010

.XXX

7

38

39

40

38

37

34

35

36

12

11

10

43

9

2

6

3

45

4

5

8

37

33

1

1314

324415

17

18

19

14 41

16

42

20

21

22

23

26

30

29

27

28

3124

25

46

46 12-587 PLUG, EXPANSION 145 10-457 WASHER 644 11-549 S.H.C.S. 143 10-653 RACE, BEARING 142 11-205 SET SCREW, SHCS 141 10-663 WASHER, THRUST 140 10-285 WASHER, SEAL 139 10-155 PLUG, DRAIN, MAGNETIC 138 10-314 NUT 737 10-279 STUD 736 10-400 O-RING 135 10-399 O-RING 134 10-669 PLUG, EXPANSION 133 10-107 S.H.C.S. 132 11-254 ANODE 131 11-204 SET SCREW, SHCS, SS 230 10-679 SEAL, OIL 129 11-518 OIL SEAL, FISHLINE CUTTER 128 10-678 CARRIER, SEAL 127 10-449 O-RING 126 10-652 BEARING, ROLLER 125 10-607 NUT, COVER, 540 124 10-668 WASHER, TAB 123 10-661 CARRIER, BEARING, R.H. 122 10-043 O-RING 121 10-605 WASHER, DISTANCE 120 10-654 RING, LOAD 119 30-262 GEAR, LOWER, 540, RH, ASSY 118 10-601 SPACER 117 10-662 NUT 116 10-596 SHAFT, PROPELLER, 540, R.H. 115 30-233 IMPELLER, OIL, ASSY 114 10-657 BEARING SET 213 10-288 SET, SHIM 112 10-260 LOCKNUT, STAKE 111 10-656 WASHER 110 10-597 PINION 19 10-659 BEARING ROLLER 18 10-613 NUT, RETAINING 17 10-685 SET, SHIM 16 10-609 SET, SHIM 15 10-649 NUT 14 10-658 SET, BEARING 13 10-651 BEARING 12 10-595 SHAFT, DRIVE 11 10-600 HOUSING, GEAR, 540 1


020. JS :YB NWARD

:YB.PPA:ELACS

554400 LLOOWWEERR GGEEAARR HHOOUUSSIINNGG AASSSS''YY,, RR..HH..

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SBL 38.64 40/31/9

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.ENIRAM DARNOK FO

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TCATNOC ESAELP Y'SSA MOTSUC A SI SRUOY FI .Y'SSA GNISUOH REWOL .H.L DRADNATS A SI SIHT **

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540 GEAR HOUSINGR.H. ASS’Y


Start to rebuild the lower gear housing (10-600, Standard or 12-037, X-Factor) by first inspecting the casting for any damage or defects. Next, thoroughly clear any sediment, metal shavings or debris that may be adhered to internal surfaces or hidden in pockets or cavities, as shown in figure 12-1. Best results can be achieved by using compressed aand a dry rag.

ir

Figure 12-2

Obtain plug (10-669). Glaze the outer diameter of it with *Loctite or equivalent and place in 9


10-66
housing. Press in until properly seated as shown in figure 12-2.
12 - 3 March 2009


Grease bearing (10-659) and place the bearing onto

Figure 12-4


TO-041
bearing driver (TO-041). Note: Do not discard cardboard from bearing.
Notice in Figures 12-3 and 12-4, the bearing numbers on bearing (10-659) are facing upward. The driver will not work if this step is missed.

12 - 4 March 2009


Insert bearing (10-659) and bearing driver (TO-041) into the bottom of the housing (with the

Figure 12-6


TO-035
bearing numbers facing upward). Pull bearing into place using bearing puller (TO-035) and 15/16 wrench as shown in figure 12-5. Note: After bearing is installed, grease cardboard and insert it into bearing to hold needles.
Press bearing race (10-653) onto shaft (10-595, Standard or 12-038, X-Factor), as shown in figure 12-6.

10Sta12X-F

3

10-65

-595 ndard -038 actor

12 - 5 March 2009


Install bearing set (10-651) and bearing set (10-658) onto shaft (10-595, Standard or 12-038, X-Factor) as shown in figure 12-7.

8

1

Figure 12-8

9


10-65

10-65


Loctite threads and screw locknut (10-649) onto shaft (10-595, Standard or 12-038, X-Factor) and torque to 150 lb-ft (203 Nm) using 1¾” socket, as
10-64 shown in figure 12-8.

12 - 6 March 2009


Place .020 in (.51 mm) shim (10-609) into housing as shown in figure 12-9.

Figure 12-10

Pound race (10-651) into the housing using impact rod (TO-037) and bearing driver (TO-040). This is demonstrated in figure 12-10.



Install the assembled shaft (10-595, Standard or 12-038, X-Factor) into the housing as shown in figure 12-11. Note: Remove cardboard from bearing (10-659) before installing shaft.

Figure 12-12

Place race (10-658) into the housing as shown in figure 12-12.



Oil nut (10-613) and screw into casting using spanner socket (TO-054). This can be seen in figure 12-13.

3

Figure 12

500 Series T

10-61
4
-14

echnical Manual

TO-05

Tighten nut until shaft has 8-12 lb-in (.90-1.36 Nm) of rolling torque as shown in figure 12-14.

12 - 9 March 2009


On vertical shaft, install gear (10-597), washer (10-656) and nut (reuse old crimp nut or 3⁄4 - 16 jam nut). Torque nut to 150

7

Figure 12-16

500 Series Techni

10-59
lb-ft (203 Nm). Refer to figure 12-15. 6
cal Manual

10-65
Note: New locknut (10-260) will be used in final
Old Crimp Nut or 3/4-16 jam nut

assembly.

Check for .024-.026 in (.61-.66 mm) gear height in 3 different places using gage (GO-020). This is demonstrated in figure 12-16. Note: If gear height is incorrect, remove shaft and install proper shimming. If gear height is correct, continue on to next step. Remove vertical shaft assembly after shimming is correct.

12 - 10 March 2009


Install .050 in. (1.27 mm) shim (10-288) into nose cone as shown in figure 12-17.

Figure 12-18

Pound race (10-657) into the nose cone using bearing driver (TO-017) and impact rod (TO-037) and alignment tool (TO-053) as shown in figure 12-18.

7

500 Ser

TO-03
TO-037
7
TO-01
ies Technical Manual

TO-053

12 - 11 March 2009


Reinstall vertical shaft assembly as shown in previous figures 12-11, 12-12, 12-13, 12-14, 12-15. Torque the nut (7

Figure 12-20

7

500 Series Techni

10-59
reuse old crimp nut, or 3⁄4 - 16 jam nut) to
6

cal Manual

10-65
150 lb-ft (203 Nm). This is shown in figure 12-19.
Old Crimp Nut or 3/4-16 jam nut

Press bearing (10-657) onto slinger (10-608) as shown in figure 12-20, and install into nose cone.

8
10-65
10-60

12 - 12 March 2009


Slide oil slinger by vertical shaft assembly and place in bearing race. This is shown in figure 12-21.

Figure 12-22

Press bearing (10-657) onto gear (30-262) as shown in figure 12-22.

10-598



Install washer (10-663), gear and spacer (10-601) onto propeller shaft (10-596, Standard or 12-147, X-Factor). This is shown in figure 12-23.

2

1

3

Figure 12-24

2 2


10-66

Install nut (10-662) and press race (10-652) onto propeller shaft (10-596, Standard or 12-147, X-Factor) as shown in figure 12-24. Install set screw (11-274) in proper hole on nut with grease and tighten to 70 lb-in (7.9 Nm). Note: One nut hole should align with counter bore that has been drilled into the shaft.
10-66 10-65
10-60

30-26

This is the proper hole that the set screw should be installed in.

12 - 14 March 2009


Install propeller shaft (10-596, Standard or 12-147, X-Factor) into housing (10-600, Standard or 12-037, X-Factor). This is demonstrated in figure 12-25.

6.

Figure 12-26

Press race (10-657) into bearing carrier (10-661, Standard or 12-146, X-Factor) using bearing driver (TO-017) and bearing driver (TO-042) as shown in figure 12-2



For X-Factor lower, press bearing (10-652) into bearing carrier (12-146) using bearing driver (TO-041) from same side as figure 12-26. As shown in figure 12-27.

Fi

50

10-652

TO-041

gure 12-28

For Standard lower, flip bearing carrier (10-661) over. Press the bearing (10-652) into the bearing carrier (10-661) using bearing driver (TO-041) as shown in figure 12-28.



Install bearing carrier (10-661, Standard or 12-146, X-Factor) ihousing (10-600, Standard or 12-037, X-Factor) as shown in figure 12-29.

nto

asher

Figure 12-30

Bend outside tab of tab w(10-668) downward 30o as shown in Figure 12-30.



Install retaining washer (10-668) into housing (10-600, Standard or 12-037, X-Factor). This is shown in figure 12-31.

Figure 12-32

Apply oil to cover nut

10-607

(10-607), and screw into casting as shown in figure 12-32.



Tighten nut with cover nut wrench (TO-052), as shown in Figure 12-33, until propeller shaft cannot move.

Figure 12-34

Place hand at top of vertical shaft, and turn back and forth lightly to feel gear mesh. The amount of movement that occurs between gear contact is the gap spacing or backlash. Spacing should be .020-.023 in (.51-.58 mm) when properly set. If adjustments are required, shimming will need to be performed at the nose cone bearing race.

6 7

Note: Put dial indicator (GO-017) on center mark II of gauge (GO-016) to correctly

500 Series Technica

GO-01

l Manual

GO-01
check backlash.
12 - 19 March 2009


To check backlash on the XFactor, use backlash che(TO-105) to extend far enougto use gauge (GO-016), as shown in Figure 12-35.

-cker

h

igure 12-36

After the correct shimming and

or).

or final assembly, add .060 in

0-

Note: Add shims to decrease the

F

backlash is determined, remove cover nut (10-607), carrier (10-661, Standard or 12-146, X-Factor) and prop shaft (10-596, Standard or 12-147, X-Fact F(1.52 mm) shims (10-685) to the race (10-658). Then retighten the nut (10-613) to 150 lb-ft (203Nm). Check to see if rolling torque is between 8-12 lb-in (.91.36 Nm) as shown in figure 12-36.

rolling torque rating. Remove shims to increase rolling torque.



igure 12-37

fter rolling torque is set,

d

einstall propeller shaft (10-).

igure 12-38 Install load ring (10-654) into

ousing (10-600, Standard or

F

Areplace used gear nut with final locknut (10-260). Loctite antorque to 150 lb-ft (203 Nm) as shown in Figure 12-37. R596, Standard or 12-147, X-Factor

F

h12-037, X-Factor). This is shown in figure 12-38.



Install washer (10-605) into housing (10-600, Standard or 12-037, X-Factor) as shown in figure 12-39.

Figure 12-40

Grease and install o-ring (10-043) as shown in figure 12-40.


540 Lower Gear Housing Assembly (Right Hand) The seal carriers (10-678, Standard and 12-146, X-Factor) are assembled differently. For instructions on 12-146 assembly, skip to page 12-24.

Standard Lower (10-678) Assembly Figure 12-41

For Standard Lower, loctite outer diameter and press seal (11-518) into the seal carrier (10-678) with numbers on seal facing downward as it is pressed in, using seal driver (TO-043) as shown in figure 12-41.

8

Figure 12-42

Loctite outer diameter and press a second seal (10-679) into the seal carrier (10-678) with cup facing upward as it is pressed in, using seal driver (TO-043).

500

2nd 10-679

11-51

Series Technical Manual 12 - 23 March 2009


Grease threads and place

9

o-ring (10-449) over the seal carrier (10-678) as shown in figure 12-43. Note: Also be sure to pack seals with grease.

Fi

50

10-44

X-Factor Lower (12-146) Assembly

gure 12-44

For X-Factor Lower, loctite outer diameter and press seal (10-679) directly into bearing carrier (12-146) with cup facing downward as it is pressed in using seal driver (TO-043), as shown in figure 12-44.

9


10-67

12 - 24 March 2009


Loctite outer diameter and press second seal (11-518) directly into carrier (12-146) with numbers on seal facing upward as it is pressed in using seal driver (TO-043) as shown in figure 12-45.

Figure 12-46


2nd 11-518

Be sure to pack seals with grease as shown in figure 12-46.

12 - 25 March 2009


Install bearing carrier (10-661, Standard or 12-146, X-Factor) into housing (10-600, Standard or 12-037, X-Factor) ashown in figure 12-47.

s

Note: Make sure the notch on the bearing carrier and housing are aligned.

Figure 12-48

Install tab washer (10-668) into housing (10-600, Standard or 12-037, X-Factor). This is shown in figure 12-48.



Apply anti seize and reinstall cover nut (10-607) into housing (10-600, Standard or 12-037, X-Factor) using spanner socket

7

(TO-052) as shown in Figure 12-49. Tighten cover nut (10-607) until the rolling torque on shaft (10-595, Standard or 12-038, X-Factor) is 20-25 lb-in (2.26-2.82 Nm).

Figure 12

500 Series T

10-60

-50 Next, turn up at least one tab from the retaining washer (10-668), as shown in figure 12-50.

At this point, the X-Factor lower is fully assembled.

echnical Manual 12 - 27 March 2009


For Standard Lower, install seal carrier (10-678) over propeller shaft (10-596, Standard) using socket spanner (TO-051). Finally, grease SHCS (11-204) and install into seal carrier (10-678) as demonstrated in f12-51.

8

4

igure

500 Se

11-20

ries Technical Manual

10-67

12 - 28 March 2009

560 Lower Gear Housing Assembly

500 Series Technical Manual 13-1 October 2009

Chapter 13


Assembly



To the Service Technician:

This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a Model 560 stern drive, it is suggested that all reassembly be done using the same shim amounts as installed by the manufacturer. While read-ing this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled.

* Note: Loctite 271 or equivalent requires 24 hours to cure.

ALL RIGHTS RESERVED

30-552MDRAWING NO.

NEXT ASS'Y

DRAWING NUMBER3/31/09

MAT'L:

.XXX

Konrad 1:2.5.X

.020


.005

APP.BY:SCALE:

.010

43

6

3

7

4

8

10

38

2

5

9

11

12

* SOLD AS GEAR SET 30-572

13

*

37

*

36

*

49

48

2829

27

17

16

15

42

44

14

1

41

40

39

40

41

21

19

18

20

2223

24

26

25

5047

35

34

33

32

31

30

46

51

51 12-587 PLUG, EXPANSION 150 30-554 LOCKNUT, FORWARD PROP, TP 149 12-529 NYLOCK NUT, REAR PROP 148 12-508 THRUST HUB, REAR PROP 147 12-509 THRUST HUB, FRONT PROP 146 10-155 PLUG, DRAIN, MAGNETIC 145 10-285 WASHER, SEAL 144 11-254 ANODE 143 10-107 S.H.C.S. 142 11-549 S.H.C.S. 141 10-314 NUT 740 10-457 WASHER 739 10-279 STUD 738 10-400 O-RING 137 10-399 O-RING 136 10-669 PLUG, EXPANSION 135 12-518 SEAL, FISHLINE CUTTER, FORWARD PROP SHAFT 134 12-526 SEAL, INNER, FORWARD PROP SHAFT 133 12-522 NEEDLE BEARING, FORWARD TP SHAFT 132 12-510 CARRIER, TWIN PROP 131 12-527 O-RING, TWIN PROP CARRIER 130 12-513 NUT, RETAINING, TP 129 12-517 SEAL, FISHLINE CUTTER, REAR PROP SHAFT 128 12-525 SEAL, INNER, REAR PROP SHAFT 127 12-520 NEEDLE BEARING, REAR TP SHAFT 126 12-523 THRUST BEARING, TWIN PROP 125 12-524 THRUST WASHER, TWIN PROP 124 12-505 THRUST CAP, TP 123 12-516 SHIM SET, THRUST CAP, TP 122 12-528 EXTERNAL RETAINING RING, TP GEAR 121 12-502 SHAFT, PROP, FORWARD TP 120 12-501 GEAR 119 12-521 BEARING SET, FORWARD TP SHAFT 118 12-515 SHIM SET, REAR BEARING, TP 117 12-503 SHAFT, PROP, REAR TP 116 30-553 TWIN PROP GEAR ASS'Y 115 12-519 BEARING SET, REAR TP SHAFT 114 12-514 SHIM SET, FRONT BEARING, TP 113 11-481 H.H.C.S. 112 12-504 WASHER 111 11-639 PINION 110 10-653 RACE, BEARING 19 10-659 BEARING ROLLER 18 10-613 NUT, RETAINING 17 10-685 SET, SHIM 16 10-609 SET, SHIM 15 10-649 NUT 14 10-658 SET, BEARING 13 10-651 BEARING 12 12-511 SHAFT, VERTICAL, LOWER TWIN PROP 11 12-500 HOUSING, GEAR, 560_TP 1


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Figure 13-1Start to rebuild the lower gear housing (12-500) by first inspecting the casting for any damage or defects. Refer to figure 13-1.

Next, thoroughly clear any sediment, metal shavings or debris that may be adhered to internal surfaces or hidden in pockets or cavities. Best results can be achieved by using compressed air and a dry rag.

Figure 13-2Obtain plug (10-669). Glaze the outer diameter of it with *Loctite or equivalent and place in housing. Press in plug until properly seated as shown in figure 13-2.

10-669



Figure 13-3Grease bearing (10-659) and place the bearing onto bearing driver (TO-041).

Note: Do not discard cardboard from bearing.

Figure 13-4Notice in Figure 13-4, the bearing numbers on bearing (10-659) are facing upward.

The driver will not work if this step is missed.



Figure 13-5Insert bearing (10-659) and bearing driver (TO-041) into the bottom of the housing (with the bearing numbers fac-ing upward).

Pull bearing into place using bearing puller (TO-035) and 15/16” wrench as shown in figure 13-5.

Note: After bearing is installed, grease cardboard and insert it into bearing to hold needles.

Figure 13-6Press bearing race (10-653) onto shaft (12-511), as shown in figure 13-6.

10-653

12-511

TO-035



Figure 13-7Install bearing set (10-651) and bearing set (10-658) onto shaft (12-511) as shown in figure 13-7.

Figure 13-8Loctite threads and screw locknut (10-649) onto shaft (12-511) torque to 150 lb-ft (203 Nm) using 1¾” socket, as shown in figure 13-8.

10-658

10-65112-511

10-649



Figure 13-9Place .020 in (.51 mm) shim (10-609) into housing as shown in figure 13-9.

Figure 13-10Pound race (10-651) into the housing using impact rod (TO-037) and bearing driver (TO-040). This is demonstrated in figure 13-10.



Figure 13-11Install the assembled shaft into the housing as shown in figure 13-11.

Note: Remove cardboard from bearing (10-659) before installing shaft.

Figure 13-12Place race (10-658) into the housing as seen in figure13-12.



Figure 13-13Oil nut (10-613) and screw into casting using spanner socket (TO-054). Refer to figure 13-13.

Figure 13-14Tighten nut until shaft has 10-15 lb-in (1.13-1.69 Nm) of rolling torque as shown in figure 13-14.

TO-054

10-613



Figure 13-15On vertical shaft, install gear (11-639), washer (12-504), and bolt (11-481). Torque bolt to 70 lb-ft (95 Nm) using a 5/8” socket. Assembly is shown in figure 13-15.

Figure 13-16Check for .024-.026 in (.61-.66 mm) gear height in 3 different places using gage (GO-025). This can be seen in figure 13-16.

Note: If gear height is incorrect, remove shaft and install proper shimming, as shown in figure 13-9. If gear height is correct, continue to the next step.

Remove vertical shaft assembly after shimming is correct.

11-639

12-504

11-481



Figure 13-17Install .020 in (.51 mm) shim (12-514) into nose cone shown in figure 13-17.

Figure 13-18Pound race (12-519) into the nose cone using bearing driver (TO-109), impact rod (TO-037) and alignment tool (TO-053) as shown in figure 13-18.

Note: Use TO-111, TO-047A, and TO-035 to pull race (12-519) out of housing when re-shimming.

TO-053

TO-037

TO-109



Figure 13-19Press bearing (12-519) onto gear (30-553) using bearing driver (TO-113), and install into nose cone as shown in figure 13-19.

Figure 13-20Reinstall vertical shaft assembly as shown in previous figures 13-11 thru 13-15. Torque the bolt (11-481) to 70 lb-ft (95 Nm). This is shown in figure 13-20.



Figure 13-21Slide thrust washer (12-524) and thrust bearing (12-523) onto rear prop shaft (12-503) as demonstrated in figure 13-21.

Figure 13-22While holding thrust bearing and washer up, press bearing race (12-520) onto rear prop shaft (12-503) using race driver (TO-115) as shown in figure 13-22.

12-503

12-520

TO-115

12-523

12-524

12-503



Figure 13-23Install rear propeller shaft (12-503) into housing (12-500) as shown in figure 13-23.

Figure 13-24Press bearing (12-521) onto gear (12-501) using bearing driver (TO-113) as shown in figure 13-24.

Note: Use gear support (TO-112) when pressing bearing onto gear. This will protect the teeth from being damaged.

12-521

12-501

TO-113

TO-112



Figure 13-25Press needle bearing (12-520) into for-ward prop shaft (12-502) using bearing driver (TO-114) as shown in figure 13-25.

Figure 13-26Carefully press bearing race (12-522) onto forward propeller shaft (12-502) us-ing race driver (TO-110) as shown in fig-ure 13-26.

Note: This race barely slides over the sealing surface on this shaft. So before press, oil all surfaces and center race so as not to scratch this sealing surface on shaft (12-502).

TO-114

12-520

12-502

12-502

12-522



Figure 13-27Slide gear (12-501) assembled in figure 13-24 onto forward prop shaft (12-502) as-sembled in previous two steps, as shown in figure 13-27.

Figure 13-28Install retaining ring (12-528) into groove on forward prop shaft (12-502) as shown in figure 13-28

12-501

12-502



Figure 13-29Place .010 (.25 mm) shim (12-516) onto end of forward propeller shaft (12-502) as shown in figure 13-29.

Figure 13-30Press thrust cap (12-505) onto end of for-ward prop shaft (12-502) in order to hold in shims (12-516) as shown in figure 13-30.

Note: When pressing thrust cap onto shaft, protect bearing surface with cloth or something as not to scratch or damage this surface.

A punch can be used to knock off thrust cap during the reshimming process.

Bearing Surface

12-505



Figure 13-31Slide forward propeller shaft assembly over the rear propeller shaft assembly into housing (12-500) as shown in figure 13-31.

Figure 13-32Slide bearing race (12-521) into housing (12-500) until it seats against bearing on gear, as shown in figure 13-32. May need to guide race down with retaining nut (12-513) in next step.

Note: This should NOT be a press fit.



Figure 13-33Oil threads and insert retaining nut (12-513) into lower housing, as shown in figure 13-33, and tighten nut down until there is a little resistance and the propel-ler shafts stabilize with spanner wrench (TO-119).

Figure 13-34Tighten nut (10-613) until vertical shaft cannot move as shown in figure 13-34.

10-613

TO-054



Figure 13-35Attach gauge (GO-026) to spline on rear prop shaft (12-503). Align indicator (GO-017) with scribed line on gauge as shown in figure 13-35.

Place hand at top of rear prop shaft and turn back and forth lightly to feel gear mesh. The amount of movement that occurs between gear contact is the gap spacing or backlash. Spacing should be .008-.010 in (.20-.25 mm) when properly set.

Note: Shimming adjustments are done be-hind race (12-519). To increase backlash, remove shims (12-514) from behind the race. To decrease backlash, add shims.

Figure 13-36After rear prop is set, attach gauge (GO-027) to spline on forward prop shaft (12-502). Align indicator (GO-017) with scribed line on gauge as shown in figure 13-36.

Turn shaft back and forth lightly to feel gear mesh. The amount of movement that occurs between gear contact is the gap spacing or backlash. Spacing should be .010-.013 in (.25-.33 mm) when properly set.

Note: Shimming adjustments are done under thrust cap (12-505). To increase backlash, add shims (12-516) under the thrust cap. To decrease backlash, remove shims.

GO-026

GO-017

GO-017

GO-027



Figure 13-37After correct shimming and backlash is determined from above, remove retaining nut, forward and rear prop shafts.

For final assembly of vertical shaft (12-511), add .065 - .070 in (1.65 – 1.78 mm) shims (10-685) to the race (10-658). Then retighten the nut (10-613) to 150 lb-ft (203 Nm). Check to see if rolling torque is between 10-15 lb-in (1.13-1.69Nm) as shown in figure 13-37.

Note: Add shims to decrease rolling torque rating. Remove shims to increase rolling torque.

Figure 13-38Reinstall pinion components. This time apply Loctite and torque the bolt (11-481) to 70 lb-ft (95 Nm) using a 5/8” socket. This is shown in figure 13-38.



Figure 13-39Reinstall rear prop shaft (12-503) and forward prop shaft (12-502) into housing.

Add .040 in. (1.02 mm) shims (12-515) to housing (12-500) as shown in figure 13-39.

Figure 13-40Reinstall race (12-521) and retaining nut (12-513).

Torque nut to 200 lb-ft (271 Nm) using spanner wrench (TO-119), as shown in figure 13-40.

Note: Please refer to table 13-1 to see what reading to set torque wrench to achieve 200 lb-ft (271 Nm).

TO-119

12-513 12-521

12-515



Diagram 13-1To achieve 200 lb-ft of torque, measure the length (L) of the torque wrench, as shown in diagram 13-1.

Locate correct length of the wrench in table 13-1 to determine the correct torque.

Table 13-1Torque Conversion Chart For Retaining Nut

Length of torque wrench (L) Reading in lb-ft (Nm) to achieve 200 lb-ft (271 Nm)

mm in. Nm lb. ft.381 15 223 164406 16 225 166432 17 228 168457 18 230 169483 19 232 171508 20 233 172533 21 235 173559 22 236 174584 23 238 175610 24 239 176635 25 240 177660 26 241 178686 27 242 179711 28 243 179737 29 244 180762 30 245 180787 31 245 181813 32 246 182838 33 247 182864 34 248 183889 35 248 183914 36 249 183



Figure 13-41Check overall rolling torque on lower gear housing assembly as shown in figure 13-41. Rolling torque should be 25-30 lb-in (2.82-3.39 Nm).

Note: Add shims (12-515) in front of race (12-521) to decrease rolling torque rating. Remove shims to increase rolling torque.

Figure 13-42With rolling torque properly set, disassemble retaining nut, bearing race, and forward propeller shaft for final assembly.

Press seal (12-525) into end of forward prop shaft (12-502) using long end of seal driver (TO-116), as shown in figure 13-42.

Note: Apply grease to inner diameter of seal for ease of installation. Apply Loctite to outer diameter of seal.

TO-116

12-525

12-502



Figure 13-43 Press seal (12-517) into end of forward prop shaft (12-502) using short end of seal driver (TO-116), as shown in figure 13-43.


Also, pack space in between two seal with grease.

Figure 13-44 Reassemble forward propeller shaft (12-502) as shown in figure 13-44. Follow procedure according to figure 13-40 and table 13-1 (page 13-23).

TO-116

12-517

12-502



Figure 13-45 Press needle bearing (12-522) into carrier (12-510) using bearing driver (TO-107), as shown in figure 13-45.

Figure 13-46 Press seal (12-526) into carrier (12-510) using the long end of seal driver (TO-117), as shown in figure 13-46.


TO-117

12-526

12-510



Figure 13-47 Press seal (12-518) into carrier (12-510) using the short end of seal driver (TO-117), as shown in figure 13-47.

Note: Apply grease to inner diameter of seal for ease of installation. Apply Loc-tite to outer diameter of seal.

Also pack space in between two seals with grease.

Figure 13-48 Place o-ring (12-527) over threads and into groove on bearing carrier (12-510) as shown in figure 13-48.

Note: Apply grease around o-ring (12-527) before assembly into housing.

Apply a Teflon/anti-seize lube to the threads on carrier (12-510) before assem-bly into housing.

TO-117

12-518

12-510



Figure 13-49 Slide carrier (12-510) over rear and forward propeller shafts and into hous-ing. Apply a marine sealing compound to the taper on this carrier as shown in figure 13-49.

Figure 13-50 Screw bearing carrier (12-510) into housing (12-500) until it seats against the taper, and torque to 175 lb-ft (237 Nm) using spanner wrench (TO-118), as shown in figure 13-50.

Note: Please refer to table 13-2 to see what reading to set torque wrench to achieve 175 lb-ft (237 Nm).

12-502

TO-118

12-510

12-500



Diagram 13-2To achieve 175 lb-ft of torque, measure the length (L) of the torque wrench, as shown in diagram 13-2.

Locate correct length of the wrench in table 13-2 to determine the correct torque.

Table 13-2Torque Conversion Chart For Bearing Carrier

Length of torque wrench (L) Reading in lb-ft (Nm) to achieve 175 lb-ft (237 Nm)

mm in. Nm lb. ft.381 15 198 146406 16 200 147432 17 202 149457 18 203 150483 19 205 151508 20 206 152533 21 208 153559 22 209 154584 23 210 155610 24 211 156635 25 212 156660 26 213 157686 27 214 158711 28 214 158737 29 215 159762 30 216 159787 31 216 160813 32 217 160838 33 218 160864 34 218 161889 35 219 161914 36 219 162



Figure 13-51 Install seal washer (10-285) and drain plug (10-155) into housing (12-500) as shown in figure 13-51.

Assembly is complete.

** During the disassembly process, most of the tools used for assembly are used the same way or in a different manner to remove components from the lower housing or to remove components from shafts. The assembly/disassembly tools are described in Chapter 2. Please refer to this chap-ter to answer questions about how a tool is used and which parts they are used for.

12-500

10-285

10-155