Synergy N7 Assembly Instructions Manual

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Congratulations on your purchase of the Synergy N7 radio controlled helicopter kit. The Synergy N7 was designed and developed by Botos Design & Distribution Inc.. The design of the Synergy N7 emerged from
many years of experience in the hobby including design, research & development, and last but not least
as a world class pilot who truly enjoys this wonderful hobby.
This radio controlled helicopter is NOT A TOY. It is a sophisticated piece of equipment, it was designed
and intended for hobby use only. If not properly assembled, maintained, and operated, it is capable of
causing property damage and bodily harm to both the operator and/or spectators. Botos Design &
from the assembly or use/misuse of this product. If you are new to the hobby we strongly recommend
seeking the help and advice from an experienced modeler.
Operating a model helicopter requires a high degree of diligence and skill. If you are new to the hobby, it
is best to seek help and guidance from experienced radio controlled helicopter pilots. This will both greatly
speed up the learning process and make it much safer for you.
For those pilots who will be operating their Synergy N7 in the United States, we strongly recommend
joining the AMA. The AMA is a non-profit organization that provides services to the model aircraft pilots. As
an AMA member, you will receive a monthly magazine entitled Model Aviation and most importantly a
liability insurance plan to cover against a possible accident or injury. All AMA charter aircraft clubs require
individuals to hold a current AMA sporting license prior to operation of their models
For further information, you can contact the AMA at
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302
(317) 287-1256
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Fuel Tank Assembly
200-414 Vent Assembly
110-332 Fuel Clunk
110-333 Fuel Clunk Tubing
106-810 Fuel Tank Stopper Grommet
110-331 Fuel Tank Stopper
317-600 N7 Fuel Tank
Note - Sealant may be required on fuel tank vent assembly threads. Any sealant which does not break down when exposed to nitro fuels may be used.
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Landing Gear Assembly
Complete Landing Gear
101-308 M3x8 Button Head
610-324 Landing Gear Strut
610-322 Skid Tube Lock x4
610-321 Skid Tube
106-966 Skid Tube Plug x4
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317-206 Hex Adapter
108-615 6x15x5 Bearing
317-207 Start Shaft Support Bearing Block
100-464 M4x4 Flat Point Set Screw
317-203 Pinion Nut (DO NOT OVER TIGHTEN)
108-105 10x19x5 Bearing
317-202 Clutch Stack Bearing Block
109-103 10x14x3 Brass Spacer
108-105 10x19x5 Bearing
317-017 N7 Helical Pinion(Factory Installed)
610-125 Clutch Bell
108-614 6x12x4 Bearing
317-205 N7 Clutch Liner (Factory Installed)
317-204 N7 Start Shaft
100-266 M2.5x6 Socket Head
NOTE - Ensure set screw meets flat spot on start shaft.
Upper Clutch Stack Assembly
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108-102 10x14x12 One Way, Clutch(Factory Installed 200-501)
200-501 Clutch Assembly
100-410 M4x10
101-306 M3x6 Button Head
110-170 Cooling Fan
317-200 N7 Fan Hub
100-312 M3x12 Socket Head(Loctite not required on pinch bolts)
Engine Washer (Included with Engine)
NOTE - Engine washer must be used for correct spacing!
Fan Hub install note- Important!
1. Slide Fan Hub on to crank shaft then take up end play with engine nut.(engine washer manditory!)
2. Tighten down pinch bolts evenly.
3. Insert crank locking tool (not included) and finish tightening engine nut. Do not over tighten crank shaft nut, only snug! It is possible to distort fan hub by over tightening.
Crank Nut (Included with Engine)
O.S. Engine 1.05
Engine/Clutch Assembly
N7 Tested with *-
- OS 1.05
- OS .91
(multiple versions)
- YS .91
*Other motors may have high vibration levels or may not run properly. Please use only motors that have been tested by Synergy.
One-Way Clutch -IMPORTANT!-
If operating in temperatures below 50F, remove grease from 10x14x12 One way. Grease will cause the rollers to stick in the outward position.
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317-403 Fan Shroud Spacer
317-403 Fan Shroud Spacer
100-376 M3x16 Set Screw
100-212 M2x12 Socket Head
106-326 26mm Hex Standoff
100-376 M3x16 Set Screw
100-212 M2x12 Socket Head
100-326 26mm Hex Standoff
317-403 Fan Shroud Spacer
317-403 Fan Shroud Spacer
NEVER APPLY LOCTITE TO BOLTS SECURING INTO PLASTIC!!!
100-376 M3x16 Set Screw
100-376 M3x16 Set Screw
110-342 Fan Shroud Right
110-343 Fan Shroud Left
Important! The included fan shroud will work with every motor on the market as of 2013. However in order to accommodate all of these motors, the fan shroud will require modifications based on your motor selection and muffler selection.
Fan Shroud Installation
DO NOT OVER TIGHTEN M2x12 BOLTS. THESE ARE IN PLASTIC!
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103-256 M2.5x6 Cross Recess
310-104 Sensor Mount Plate
310-110 Frame Spacer
Gyro Mount Plate Assembly
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310-105 CF Lower Frame Brace
310-110 Frame Spacer
103-256 M2.5x6 Cross Recess
Rear Frame Brace Assembly
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100-206 M2.5x6 Cross Recess
310-110 Frame Spacer
317-103 CF Radio Plate
Radio Plate Assembly
Tip - Sanding carbon edges to prior to assembly will prevent wire chafing.
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317-503 N7 Auto Hub Sleeve
317-505 N7 Auto Hub Delrin Shim
108-166 16x22x16 One-Way Bearing, Auto Hub
317-502 N7 Bronze Bushing
200-415 N7 Auto Hub Assembly
Includes -
317-501 Auto Hub (not sold separately)
108-166 16x22x16 One-Way Bearing
610-153 N7 Bronze Bushings
317-502 N7 Bronze Bushing
317-139 139T Helical Main Gear
101-308 M3x8 Button Head
317-505 N7 Auto Hub Delrin Shim
103-256 M2.5x6 Cross Recess
320-154 54T Spur Gear
317-500 N7 Spur Gear Hub
Important - Bronze bushings must be secured with green or red loctite!
Main Transmission Assembly
DO NOT OVER TIGHTEN!
DO NOT OVER TIGHTEN!
IMPORTANT! Do not use grease for one way clutch lubrication! Use light oil such as Triflow.
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Front Tail Transmission Assembly
108-124 12x18x4 Radial Bearing
320-301 Front Mushroom Gear Bearing Block
320-218 18T Front Trans Mushroom Gear
100-351 M3 Nylock Nut
100-372 M3x12 Set Screw
100-354 M3 Washer
108-510 5x10x4 Radial Bearing
320-302 Bevel Gear Top Bearing Block
320-406 11mm Pin for 18T Bevel Gear
320-303 Spur Gear Bottom Bearing Block
108-593 5x9x3 Radial Bearing
320-408 Spur Gear Shaft
320-111H 11T Hard Coat Spur Gear
320-407 2mm Spur Gear Pin
320-101 TranSupport CF Plate
320-103 TranSupport Standoff
101-306 M3x6 Button Head x12
100-372 M3x12 Set Screw
Important! - TIghten and secure set screw with loctite. This set screw secures bevel gear pin.
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320-118 Front Trans Bevel Gear
IMPORTANT! - Any screw which is metal to metal needs loctite! Clean oil from bolts and apply blue loctite.
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101-306 M3x6 Button Head
310-111 Main Boom Clamp
310-111 Main Boom Clamp
317-104 N7 CF Lateral Frame Brace
100-310 M3x10 Socket Head
Main Boom Clamp Assembly
Do not tighten boom pinch bolts yet!
Pinch bolts do not apply loctite!
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100-316 M3x16 Socket Head
108-373 3x7x3 Radial
107-106 Pivot Ball
107-106 Pivot Ball
108-373 3x7x3 Radial
106-301 M3 Shim
317-301 Tail Offset Bell Crank Mount
109-352 3x5x2 Brass Spacer
317-300 Tail Offset Bell Crank
Tail Offset Bell Crank Assembly
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Main Shaft Bearing Blocks
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108-105 10x19x5 Radial Bearing
108-105 10x19x5 Radial Bearing
310-150 Main Shaft Bearing Block E6/7
310-151 Third Main Shaft Bearing Block
Important -
Keep this orientation in mind for future reference. Make sure bearing block and bearing orientation is correct. Top bearing is facing up, middle beaing is facing down, lower bearing is facing up.
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Right Frame Assembly
Step 1
100-308 M3x8 Socket Head
100-308 M3x8 Socket Head
100-306 M3x6 Socket Head
101-408 M4x8 Button Head
305-121 Key Chain Canopy Mount, Female 21mm
100-372 M3x12 Set Screw
317-102 Front Frame Doubler
310-110 Frame Spacer
317-400 4mm Frame Spacer
317-400 4mm Frame Spacer
317-101 N7 Rear CF Frame
317-100 N7 Front CF Frame
101-408 M4x8 Button Head
Completed View
DO NOT FULLY TIGHTEN BOLTS! FRAMES MUST BE SQUARED IN FUTURE STEP!
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Right Frame Assembly
Step 2
610-123 Standard Servo Mount
100-212 M2x12 Socket Head
106-115 Servo Hold Down
100-206 M2x6 Socket Head
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101-306 M3x6 Button Head
100-306 M3x6 Socket Head
Right Frame Assembly
Step 3
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Right Frame Assembly
Step 4
101-306 M3x6 Button Head
Important!
Frame is slotted to allow for two different tail gear ratios! 11T(4.9:1) Slide Fore (Stock Ratio) 12T(4.5:1) Slide Aft (Optional Ratio)
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610-123 Standard Servo Mount
100-212 M2x12 Socket Head
106-115 Servo Hold Down
100-206 M2x6 Socket Head
Standard size throttle servo
Please choose throttle servo that is same speed or faster than your cyclic servos.
Not Included
317-100 N7 Front CF Frame
Left Front Frame and Throttle Servo Assembly
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317-102 Frame Doubler
101-410 M4x10 Button Head
100-308 M3x8 Socket Head
100-306 M3x6 Socket Head
100-308 M3x8 Socket Head
100-306 M3x6 Button Head
100-306 M3x6 Socket Head
100-372 M3x12 Set Screw
305-121 Key Chain Canopy Mount, Female 21mm
Left Frame Assembly
Step 2
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317-402 Engine Mount, Left
317-401 Engine Mount, Right
100-310 M3x10 Socket Head
IMPORTANT! Engine Mount blocks are side specific!
Engine mount blocks are marked with an L for LEFT and R for RIGHT. (Viewing top down with the tail pointed towards you, nose of the helicopter pointed away.)
Engine Mounts
Note - These two holes are intended for nitro engines
Note - These two holes are intended for future gasoline motors.
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Completed View
100-416 M4x16 Socket Head
100-308 M3x8 Socket Head
Engine Install
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Anti Rotation Frame Brace and Frame Square
310-106 CF Anti-Rotation Brace
101-306 M3x6 Button Head
90.00°
Check main frames to ensure they are 90 degrees and tighten all bolts.
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Landing Gear and Bottom Brace Install
100-316 M3x16 Socket Head
100-308 M3x8 Socket Head
100-266 M2.5x6 Socket Head
317-106 CF Bottom Frame Brace
100-308 M3x8 Socket Head
100-306 M3x6 Socket Head
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Clutch Stack and Governor Sensor
100-308 M3x8 Socket Head
100-308 M3x8 Socket Head
106-952 Governor Sensor Mount Bracket
317-208 Frame Saver
106-930 M3 Step Washer
100-308 M3x8 Socket Head
TIP - Take this opportunity to install the clutch magnet and RPM Sensor. These items should be provided with the Governor electronics.
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101-306 M3x6 Button Head
101-306 M3x6 Button Head
100-312 M3x12 Socket Head
100-312 M3x12 Socket Head
405-101 U-Channel Canopy Post
405-101 U-Channel Canopy Post
Gyro Plate and Radio Plate Install
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Fuel Tank Assembly Page 1
317-601 N7 Fuel Tank Edge Grommet
317-601 N7 Fuel Tank Edge Grommet
Fuel Tank Installation
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100-261 M2.5x10 Socket Head
106-115 Servo Hold Down
Perform this step for all thee cyclic servos!
High Quality Cyclic Servo (Not Included)
Cyclic Servo Installation
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100-210 M2x10 Socket Head
100-251 M2 Regular Nut
320-502 Torque Tube End
320-504 O-Ring
108-814 8x14x4 Radial Bearing
Apply RED Loctite to secure bearing to Torque Tube. Do not apply loctite to plastic
Important! - Secure Torque Tube end with quality RED Loctite!
Note - Install bearings on torque tube shaft before installing torque tube ends. Bearings will not slide over ends.
320-503 Torque Tube Bearing Housing
270mm
270mm
Unequal Bearing Spacing
Torque Tube Assembly
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320-500 Torque Tube
260mm
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107-100 Ball Link
305-311 Tail Push Rod End
106-965 Tail Push Rod Sleeve (Teflon)
315-111 Tail Control Rod 728mm
IMPORTANT! - Tail Control Rod End must be secured with high quality glue such as JB Weld. We highly recommend long curing formulas for the best results. Do not use CA for this application! You will encounter failures!
Note - Lightly sand carbon tail
control rod prior to securing with
JB Weld!
Note - Tail push rod ends will slide through tail control guides.
Tail Control Rod Assembly
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315-117 Boom Support 580mm
115-119 Boom Support End
115-119 Boom Support End
Notes -
1. Use Epoxy or JBWeld
2. Ensure ends are in alignment while glue sets
Top - attaches to boom clamp
Bottom - attaches to frames
Sand Ends Lightly Before applying glue!
Sand Ends lightly before applying glue!
Boom Support Assembly
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315-140 812mm Boom
115-114 Tail Control Guide
610-128 Boom Support Clamp, Lite
Note - Tail Boom will remain flush with front boom mount. Do not push tail boom all the way forward! This will cause improper mesh of the bevel gears.
Note - Use silicone based grease for installation of torque tube assembly into the tail boom.
Torque Tube Assembly (Page 28)
Tail Boom Install
Do not forget to tighten the two pinch bolts!
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Tail Control Rod and Boom Support Install
Tail Control Rod Assembly (Page 29)
Boom Support Assembly (Page 30)
101-412 M4x10 Button Head
101-416 M4x16 Button Head
317-400 4mm Frame Spacer
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305-309 Tail Box
108-124 12x18x4 Radial Bearing
320-405 Tail Box Bearing Spacer
101-306 M3x6 Button Head
108-613 6x13x5 Raidal Bearing
305-307 Output Shaft Spacer
615-124 Tail Output Shaft 6mm
305-308 Tail Box Spacer
305-618 18T Mushroom Tail Bevel Gear
305-518 18T Tail Bevel Gear
317-302 N7 Vertical Tail Fin CF
305-305 Tail Box Plate Left
305-306 Tail Box Plate Right
108-613 6x13x5 Radial Bearing
101-306 M3x6 Button Head
100-325 M3x25 Socket Head
100-306 M3x6 Socket Head
100-366 M3x6 Set Screw
Tail Box Assembly
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108-124 12x18x4 Radial Bearing
320-406 11mm Pin for 18T Bevel Gear
This set screw is very important as it locks the pin in place which secures the tail bevel gear. Make sure to apply loctite and secure this set screw!
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100-306 M3x6 Socket Head
100-354 M3 Washer
108-503 5x10x3 Radial
106-501 5mm Shim
Small OD Small ID
Large ID Large OD
Ball Race
515-525 Tail Blade Grip
108-503 5x10x3 Radial
107-106 Pivot Ball
108-511 5x10x4 Thrust Bearing
IMPORTANT! - Apply Grease to Thrust Bearing Ball Race
615-324 Tail Rotor Hub (for 6mm shaft)
Tail Rotor Hub Assembly
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Pitch Slider Assembly
615-319 Tail Pitch Slider Bushing (for 6mm shaft)
108-812 8x12x2.5 Radial Bearing
107-103 2mm Pivot Ball Short
115-319 Tail Bearing Ring
108-812 8x12x2.5 Radial Bearing
115-322 Tail Pitch Link
106-813 Tail Slider Lock Ring
606-921 Tail Pitch Link Pin
506-920 E-Ring
115-321 Pitch Plate
Use Medium CA to secure 2mm pivot ball
1. After installing lock ring be sure that the radial bearings do not have lateral load on them. Adjust lock ring as needed to ensure smooth operation.
2. Secure lock ring with CA or Epoxy
Red Loctite Tail Pitch Slider to Tail Pitch Plate for extra security.
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100-351 M3 nylock Nut
305-310 E5 Tail Lever Mount
101-308 M3x8 Button Head
106-301 M3 Shim
108-373 3x7x3 Radial Bearing
109-355 3x5x5 Brass Spacer
115-316 Tail Rotor Bell Crank
108-373 3x7x3 Radial Bearing
100-330 M3x30 Socket Head
107-104 2mm Pivot Ball
100-251 M2 Nut
Tail Rotor Bell Crank Assembly
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IMPORTANT!!! Note orientation of tail blade grips. The tail will rotate clockwise. The tail blade grips should lead with the pivot ball at the leading edge of the tail blade. This does not affect the performance off the tail rotor in any way.
IMPORTANT!!! Check left and right tail rotor direction as well as tail gyro correction direction after assembly is completed.
Completed Tail Box Assembly
Existing Tail Pitch Slider Assembly (Not Included)
Existing Tail Hub Assembly (Not Included)
Tail Box Completion
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Tail Box Install
Slide tail box assembly on to tail boom. Ensure torque tube is aligned with mushroom bevel gear.
IMPORTANT! If you wish to use boom pinning feature you must drill 3mm hole! Follow these steps.
1. Install Tail Box
2. Ensure Tail Box is vertical
3. Mark drill location
4. Remove tail box and torque tube
5. Drill 3mm hole at marked location
101-306 M3x6 Button Head
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Main Shaft and Transmission Install
317-410 N7 Main Shaft
610-150 Main Shaft Collar
100-320A M3x20 Special Bolt
100-325A M3x25 Special Bolt
320-411 Jesus Bolt Collar
100-351 M3 Nylock Nut
100-261 M2.5x10 Socket Head
Use the 10mm main shaft shim if you have vertical movement in the main shaft after assembly. This is completely normal and within tolerances.
Over tightening will create unwanted stess on these bolts
DO NOT OVER TIGHTEN!!
DO NOT OVER TIGHTEN SPECIAL BOLTS!!!
109-110 10mm Main Shaft Shim (Optional)
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100-306 M3x6 Socket Head
107-106 Pivot Ball 3x4.5
310-145 Blade Bolt Adapter 5mm
305-204 Head Axle Pivot
606-803 Head Damper
120-114 Head Axle
100-512 M5x12 Socket Head
100-554 5mm Washer
106-803 8x1mm Shim
108-816 8x16x5 Radial
106-801 8x.5mm Shim
108-817 - 8x16x5 Thrust bearing
520-514 FBL Main Blade Grip
100-308 M3x8 Socket Head
Rotor Head Assembly
*Note Thrust Bearing Order Large ID Large OD - Inside Position Small ID Small OD - Outside Position
310-153 E7SE Blade Grip Arm
APPLY GREASE!
APPLY GREASE!
DO NOT OVER TIGHTEN PITCH ARM BOLTS!
310-201 E7SE Head Block
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YOU WILL STRIP THE M3x6 IF YOU ARE NOT CAREFUL USE GENTLE FORCE AND RED LOCTITE!
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Swash Follower Arm Assembly
106-301 M3 Shim
108-383 3x8x3 Radial Bearing
305-208 E5 Washout Control Arm HD
109-352 3x5x2 Brass Spacer
108-383 3x8x3 Radial Bearing
108-383 3x8x3 Radial Bearing
100-323 M3x23 Socket Head
100-316 M3x16 Socket Head
109-352 3x5x2 Brass Spacer
108-383 3x8x3 Radial Bearing
107-100 Ball Link
100-272 M2.5x12 Set Screw
305-207 E5 Ball Link Adapter
106-301 M3 Shim
Note - Do not tighten 100-323 bolt until the
next page. These will pinch and secure the main shaft.
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IMPORTANT!
Remove M2.5x12 Set Screw from Ball Link Adapter before attempting to remove M3x16 Socket Head. The M2.5x2 Set Screw is sitting against the M3x16 bolt and will destroy the bolt threads and the Ball Link Adapter threads if you attempt to remove the bolt without rst removing the set screw.
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Swash Plate Assembly
107-108 Pivot Ball Long x3
107-106 Pivot Ball x4
108-373 3x7x3 Radial Bearing
100-316 M3x16 Socket Head
109-352 3x5x2 Brass Spacer
100-312 M3x12 Socket Head
100-364 M3x4 Set Screw
200-401 Swash Plate Assembly
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IMPORTANT! Do not forget to tighten pinch bolts equally on both sides!
IMPORTANT! Do not over tighten 100-320A Bolt!
100-320A M3x20 Special Bolt
100-351 M3 Nylock Nut
Pitch Link
x2
26.50mm
107-100 Ball Link
107-048 48mm Link Rod
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Rotor Head Install
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100-352 M3 Nut
107-106 Pivot Ball
100-251 M2 Nut
100-206 M2x6 Socket head
310-107 CF Servo Arm
IMPORTANT! - Use Red Loctite to secure Pivot Ball to M3 Nut
Servo Horn Assembly
Note - It is best to determine servo horn position clostest to 90 degrees before fixing CF servo arm to the servo arm wheel.
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Servo Horn Bolt (Not Included)
TIP -
Center all servos electronically then select the best position on the spline for correct 90 degree geometry
Mount all three cyclic servo horns at this time.
Servo Horn Install
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X3
20mm
107-100 Ball Link
107-043 43mm Link Rod
CCPM Linkage
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317-303 Carbon Control Rod, 225mm
305-311 Tail Push Rod End
107-100 Ball Link
IMPORTANT! - Clean the inside diameter of the tail push rod ends with degreaser before gluing.
IMPORTANT!
- Tail Control Rod End must be secured with high quality glue such as JB Weld. We highly recommend long curing formulas for the best results. Do not use CA for this application! You will encounter failures!
Front Tail Control Rod Assembly
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Control Rod Assembly (Page 47)
107-104 Pivot Ball 2mm
100-252 M2 Nylock Nut
Servo Horn
Servo Screw
Note -
Pivot ball should be installed at 16mm or more from the center of the servo horn! This is important for correct tail servo throw and resolution
Front Tail Control Rod Install
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43mm
Throttle Linkage
107-100 Ball Link
107-100 Ball Link
107-065 65mm Link Rod
107-104 Pivot Ball 2mm
100-252 M2 Nylock Nut
100-252 M2 Nylock Nut
107-104 Pivot Ball 2mm
Note- Place 2mm pivot ball at 16mm from center of the plastic horn on both servo and carb barrel.
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305-125 Key Chain Canopy Mount Male
305-126 Key Chain Canopy Grommet
101-306 M3x6 Button Head
106-805 Canopy Washer Nylon
Canopy Assembly
405-100 U-Channel Female
317-700 N7 Canopy
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100-535A M5x35 Socket Head
100-551 M5 Nylock Nut
Blade Spacers (Included with blades)
696mm Main Blades (Not Included)
Main Blade Install
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106mm Tail Blades (Not Included)
100-351 M3 Nylock Nut
100-316 M3x16 Socket Head
106-804 Tail Blade Washer
Tail Blade Install
IMPORTANT!!! Note orientation of tail blade grips. The tail
will rotate
clockwise
. The tail blade grips should lead with the pivot ball at the leading edge of the tail blade. This does not affect the
performance of the tail rotor in any way.
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389mm
1322mm
279mm
1549.50mm
215mm
Measurements
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