Kyosho Caliber 60 Instruction Manual
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Kyosho Caliber 60 Instruction Manual

Kyosho Caliber 60 Instruction Manual

Radio controlled engine powered helicopter
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Before commencing assembly, please read these instructions thoroughly.

INSTRUCTION MANUAL

RADIO CONTROLLED ENGINE POWERED HELICOPTER
© 1999 KYOSHO
SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
For Advanced

SAFETY PRECAUTIONS

This radio control model is not a toy.
This is a kind of machine including a rotor which rotates with
high speed and has a possibility to be dangerous. You are
responsible for this model's assembly, safe operation (place
to fly, frequency) check and adjustment of the model.
Assemble this kit only in places out of children's reach!
Take enough safety precaution before and after operation.
After every flight, inspect screws and nuts for looseness, and
parts for wear. Any damaged parts should be immediately
replaced, repaired or adjusted for safe operation.
Use only Kyosho genuine parts for replacement.
Failing to do so will result in accidents or malfunction of the
model. Kyosho do not take responsibilities for the accidents
and crashes if using the parts which are not Kyosho genuine
ones.
Always keep this instruction manual ready at hand for quick
reference, even after completing the assembly.
THE FINEST RADIO CONTROL MODELS
flyers.
No. 21865
R

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  • Page 1: Instruction Manual

    Failing to do so will result in accidents or malfunction of the model. Kyosho do not take responsibilities for the accidents and crashes if using the parts which are not Kyosho genuine ones. Always keep this instruction manual ready at hand for quick reference, even after completing the assembly.

  • Page 2: Required For Operation

    REQUIRED FOR OPERATION (1) Radio for engine-powered R/C helicopters Radio for engine-powered R/C helicopters, and dry batteries SUITABLE SERVOS ONVERSION RATE GYRO PULSE CODE MODULATION CONNECT 9 CHANNEL RECEIVER 33~36mm This kit requires an EMS system radio for 39~41mm engine-powered R/C helicopters with 5 19~20mm servos and 1 gyro.

  • Page 3: Radio Preparation

    RADIO PREPARATION Set up the radio as explained below. Aileron Servo (GY501 ) Gyro(In GY501 case) ONVERSION PULSE CODE MODULATION RATE GYRO 9 CHANNEL RECEIVER CONNECT R149DP R149DP Receiver Rudder Servo Nicd Battery Pitch Servo Receiver Switch Terminal to charge 1024 ZH Transmitter EMS setting...

  • Page 4: Before You Begin

    BEFORE YOU BEGIN (1) Read through the manual before you begin, so you will have an overall idea of what to do. Check all parts. If you find any defective or missing parts, contact your local dealer or our Kyosho Distributor. Example...
  • Page 5 -rence signal and LED lamps whether somebody else is on your fre-quency or not! PERSONAL BAND MONITOR KYOSHO CORPORATION No.80591 (40MHz) No.80592 (72MHz) No.80591 6,000 Special crystals are JRMSA available at Kyosho! KYOSHO CORPRATION...
  • Page 6 In Order to understand full assembly sequence, this instruction manual shows the complete assembly of this model, even though some elements are supplied pre-built. please refer to it when carrying out maintenance or replacing parts. CA-1.CA-2 Ladder Frame Ball Bearing pre-installed 12x24x6mm Ball Bearing 7x17x5mm...
  • Page 7 CA-B,CA-1,CA-2 Ladder Frame 4x10mm Cap Screw 3x10mm Cap Screw 3x10mm 4x10mm CA-C,CA-1,CA-2 Servo Plate 3x10mm glued 3x10mm Outside Cap Screw Inside 3x6mm Cap Screw 3x6mm 5x11x5mm F 3x14mm Flanged Ball Bearing 3x14mm Set Screw 3x6mm 3x10mm 3x10mm Short Body Mount 3x14mm Part bags used.
  • Page 8 CA-B Pulley pre-assembled 10x19x5mm Ball Bearing Mark should be this way down Be certain to apply 96506 ball diff.grease 10x16x12mm One Way Bearing Bottom CA-B Pulley CA-3 3x5mm 7x13x1.5mm Counter Gear Collar Be careful not for being bent. 3x5mm Set Screw 3x5mm Pay close attention here! Part bags used.
  • Page 9 CA-B,CA-3 Main Mast 3x12mm Cap Screw 3x24mm Cap Screw Nylon Nut Note:Be sure to install tightly against upper bearing. 3x12mm 3x24mm 5x10mm CA-B,CA-4 Clutch 12x21x5mm Ball Bearing Supplied with the engine. pre-assembled Supplied with the engine. Clutch Shaft Washer 5x10mm Set Screw pre-assembled Engine.
  • Page 10 CA-B,CA-4 4x10mm Cap Screw 4x10mm Every Screw CA-4 4x15mm Cap Screw 4x15mm Part bags used. Assemble left and right sides the same way. Apply threadlock (screw cement).

  • Page 11: Cooling Fan

    CA-B,CA-4 Cooling Fan 4x20mm Cap Screw 6x13x5mm Ball Bearing 4x20mm pre-assembled CA-4 Cooling Fan 3x6mm Cap Screw 3x6mm CA-4 Cooling Fan Cover 3x8mm Cap Screw 3x8mm Part bags used. Assemble left and right sides the same way. Apply threadlock (screw cement).
  • Page 12 CA-5 Seal Nut Seal Washer Tightten after assembly has been inserted in fuel tank CA-5 Tank Holder (A) Tank Holder (B) Carburetor Muffler Part bags used. Assemble left and right sides the same way. Apply threadlock (screw cement).
  • Page 13 CA-C,CA-6 3x5mm Set Screw 3x12mm Cap Screw 3x8x1mm Washer 3x5mm 3x8x1mm 3x12mm Do not tighten excessively. CA-B,CA-7 Elevator Lever 2x8mm Cap Screw This portion is cut in kit Pre-assembled 2.6x12mm Cap Screw 3x7x3mm Ball Bearing 2x8mm 2x3x4mm 2.6x12mm Collar 3x6mm CA-7 Elevator Lever 3x6mm...

  • Page 14: Swash Plate

    CA-B,CA-7 Aileron Lever 3x8x4mmF Ball Bearing 3x6x4.5mm Collar M3-11 M3-5 M3-11 Linkage Ball M3-5 Linkage Ball pre-assembled bearing Every Screw 2x7mm CA-B Swash Plate pre-assembled 2x7mm RT/H Screw In order to remove play on No. 648 upper and lower 2x7mm plate, pressure to bearings M3-5 are applied.
  • Page 15 CA-7 Aileron Lever Note the direction. 3x22mm 4x20mm Cap Screw 3x10mm 3x8x0.5mm 3x22mm Cap Screw Aileron Lever 3x10mm Cap Screw 4x20mm 3x8x0.5mm Washer 3x22mm 652 3x6x4.5mm Collar Aileron Lever CA-7 3x3mm Set Screw 3x3mm Please reverse 653 when 649 does not move smooth. 32mm approx.
  • Page 16 CA-B Mixing Lever pre-assembled 3x7x3mmF Ball Bearing 652 3x6x4.5mm Collar M3-11Linkage Ball CA-B Main Rotor Grip pre-assembled 3x8mm Cap Screw 3x10mm 3x10mm Cap Screw 3x15mm Cap Screw 3x15mm 3x8mm CA-B Main Rotor Head pre-assembled 3x6mm Cap Screw 3x6mm Every screw Assemble left and right sides Assemble as many times as specified (here: twice).
  • Page 17 CA-B Main Rotor Head pre-assembled Seesaw Damper 3x23.8mm 2.6x4mm Needle Pin 2.6x4mm Cap Screw 2.6x4mm CA-B Main Rotor Grip pre-assembled Note the different hole sizes in 8x16x5mm Ball Bearing Large Small 8x16x5mm Thrust Bearing Part bags used. Apply threadlock Assemble as many times as specified (here: twice). Apply grease.

  • Page 18: Main Rotor Head

    CA-B Main Rotor Head pre-assembled Spindle Shaft Collar 4x12x2mm Spindle Washer 4x10mm Cap Screw Warning! Be sure to tighten 4x10 cap screws. If coming off during flights, you lose 4x10mm control of your airplane. It may lead accidents! CA-8 Hiller Control Lever pre-assembled Linkage Ball 2x16mm...
  • Page 19 CA-8 Stabilizer Seesaw M3-5 M3-5 Linkage Ball 4x8x3mm Ball Bearing Bearing pre-installed CA-8 Main Rotor Head 3x4x4.5mm 3x8mm Collar 4x9x4mm F Flanged Ball Bearing 3x8mm 3x8mm Cap Screw Bearing pre-installed CA-A,CA-8 Main Rotor Head 4x4mm 446N Set Screw 4x4mm 4x4mm 4x4mm 4x4mm Part bags used.
  • Page 20 CA-8,CA-11 Stabilizer Blade approx. 27mm 4x4mm Set Screw 4x4mm Tighten set screw so that Stabilizer Blades are equally spaced. Main Rotor Head Ensure that are parallel. Parallel Parallel CA-8 Main Rotor Head 4x25mm Drag bolt Nylon Nut Assemble left and right sides Part bags used.
  • Page 21 Phase Adjustment 446N 446N Adjust this place in order are in line 446N CA-9 59mm Adjustable Rod approx. 59mm 2.3x18mm Adjustable Rod 48mm approx. 48mm 2.3x57mm Adjustable Rod 2.3x70mm Adjustable Rod 2.3x80mm Adjustable Rod 35mm approx. 35mm approx. 5mm This portion is cut in kit Part bags used.

  • Page 22: Tail Rotor

    CA-B,CA-10 Tail Rotor 3x4mm Note the direction. Set Screw (Special type) 6x10x3mm 3x4mm Ball Bearing Reverse Thread 2x8mm 260G Fasten both 3x4mm set screws onto the points indicated. pre-assembled bearing CA-10 Tail Rotor 5x10x4mm Ball Bearing 3 6mm 3x15mm Cap Screw 3x6x0.5mm Washer 3 15mm...
  • Page 23 CA-10 Tail Rotor pre-assembled 5x14x5mmF Flanged Ball Bearing CA-10 Tail Rotor 2x6mm 3x8x0.5mm 3x3mm Cap Screw Washer 3x3mm Set Screw 3x6mm Cap Screw 3x8x0.5mm 3x6mm Fasten both 3x4mm set screws 2x6mm onto the flat indicated. 2x6mm CA-10 Tail Rotor 2 mm Cap Screw 4x7x2.5mmF Flanged Ball Bearing...
  • Page 24 CA-B,CA-10 Tail Pich Lever Ball Bearing pre-installed 2x5x2.3mmF Flanged Ball Bearing 2x8mm RT/H Screw 2x8mm Linkage Ball 2x4x0.5mm 2x8mm CA-10 2x8mm Tail Pitch Lever Be sure smooth movement 2x6mm 2x6mm Note the direction! when you assemble Cap Screw 2x4x0.5mm 2x8mm Cap Screw 3x3mm Fasten both 3x4mm set screws...
  • Page 25 CA-11 Tail Boom 2.6x12mm Cap Screw 2.6x12mm 2.6x12mm CA-11 3x8mm Tail Boom 3x8mm Cap Screw Nylon Nut Tail Boom Front Part bags used. Temporarrily tighten.
  • Page 26 3x15mm CA-11 Tail Boom 3x25mm 3x15mm Cap Screw 3x25mm Drag Bolt CA-11 Tail Boom 3x6mm Cap Screw Strain this way lightly. 3x6mm Do not tighten excessively. Horizontal CA-11 3x8mm Cap Screw 3x8mm Part bags used. Apply threadlock Assemble in the Pay close attention here! Tentatively tighten.
  • Page 27 CA-A,CA-11 Tail Short Pipe 2x8mm Cap Screw Long Pipe 2x8mm CA-A,CA-11 Tail Boom 3x10mm 3x8x0.5mm Cap Screw Washer 3x12mm Cap Screw 3x15mm Cap Screw Nylon Nut 3x10mm 3x8x0.5mm 3x15mm 3x8x0.5mm 3x8x0.5mm Short Pipe 3x15mm Long Pipe 3x8x0.5mm 3x10mm 3x12mm Part bags used. Apply instant glue (CA glue, super glue).
  • Page 28 Switch Switch Process the edge in order that the edge does not damage cords of radio. File the edge smooth. Switch CA-12 Throttle Control Servo 2.6x15mm Cap Screw Throttle Control Servo 2.6x15mm CA-12 Aileron,Pitch Control Servo Aileron Control Servo 2.6x15mm Cap Screw Pitch Control Servo 2.6x15mm...
  • Page 29 CA-12 Elevator Control Servo Radio Control Installation 2.6x15mm 2.6x15mm Cap Screw Attach Elevator servo inside Radio Control Installation Double-sided Tape Gyro Amp Gyro Receiver NiCd Battery Make sure the gyro does not touch the frame. Refer to radio instruction manual for correct servo connection. Be careful that line is not damaged with edge.
  • Page 30 Servo Horns Futaba 14mm 17~20mm 15mm 14mm 15mm For Aileron Control Servo For Throttle Control Servo For Rudder Control Servo For Elevator Control Servo For Pitch Control Servo CA-12 Servo Horns 2x10mm RT/H Screw 2x10mm 2x10mm Throttle Lever Linkage Ball 2x10mm 2x10mm For Aileron Control Servo...

  • Page 31: Rudder Linkage

    CA-12 Rudder servo 2.6x12mm Cap Screw Neutral Stick Servo 2.6x12mm CA-A,CA-12 Rudder Linkage CA-12 Rudder Linkage Guide p r o p r o Attach horizontally. p r o Part bags used. Apply instant glue Apply threadlock Must be purchased Assemble as many times as Assemble in the separately! (screw cement).
  • Page 32 CA-11,CA-12 Rudder Linkage Adjust Rudder Servo Holder in accordance with the length of Parallel Throttle Linkage Neutral Stick Assemble left and right sides the same way. Part bags used. Must be purchased separately! True-to-scale diagram.
  • Page 33 Aileron Linkage Neutral Stick Horizontal Assemble Pitch Servo Neutral stick same way Elevator Linkage Make horizontal then fix tentatively tightened parts. Neutral Stick Assemble left and right sides the same way. Must be purchased separately! True-to-scale diagram.
  • Page 34 CA-C,CA-14 Tail Fin CA-13 Tail Fin 3x6mm 3x8mm Cap Screw Cap Screw 3x8x0.5mm Washer 3x8mm 3x6mm Apply threadlock Part bags used. (screw cement).
  • Page 35 Muffler Muffler Examination for movement Ensure all screws,etc,are properly tightened. Ensure that servo movements are unrestricted. Examine linkage rods for smooth movement. Main Rotor Pitch, Swashplate,Tail Pitch and Throttle all operate smoothly. approx. 20mm approx. 20mm When pitch moves up and down,Tilt of swash- plate caused by the difference of servo pefor- mance is adjusted by fine tuning of ATV travel adjustment, whole stroke is adjusted by AFR.
  • Page 36 CA-D,CA-13 Body Grommet CA-14 Decal Apply decals as illustrated. The decal numbers between brackets are for the opposite side. BODY MOUNT COMES HERE BODY MOUNT COMES HERE Assemble left and right sides the same way. Must be purchased separately! Drill holes with the specified diameter (here: 8mm).
  • Page 37 CA-13 Body 3x10mm 3x10mm Cap Screw Washer 3x10mm 3x10mm 3x10mm CA-8 Main Rotor Drag Bolt Main Rotor Nylon Nut Pitch reference table 100% Stick Position Center High Hovering and Usual Flight + 1.5 + 5.5 Loop / Stall Turns Roll -0.5 + 8.5 + 11...
  • Page 38 OPERATING YOUR MODEL SAFELY WARNING: Do NOT operate the helicopter in the following places and situations: (Non-observance may lead to accidents!) Always check the radio batteries! As the radio batteries get weaker, transmission and reception decrease. You may lose control of your model when opera- ting it under such conditions.

  • Page 39: Maintenance

    /or damage to property! Wipe off any dirt or oil deposits from your helicopter. Wearing Parts WARNING: When replacing defective parts with new ones, please only use genuine Kyosho branded items. Ball End / Linkage Ball Swash Plate...

  • Page 40: Parts List

    PARTS LIST DESCRIPTION DESCRIPTION Key No. Bag No. Q'ty Key No. Bag No. Q'ty 8x16x5mm 8x46x5mm Ball Bearing Elevator Shaft Thrust Ball Bearing Aileron Lever Spindle Washer 3x4x4.5mm 3x4x4.5mm Collar Slide Bush Swash Plate 6x10x3mm Ball Bearing Slide Block (A) 6x10x3mm Tail Pitch Yoke Washout Arm...
  • Page 41 < EXPLODED VIEW (1) > CA6008 CA6008 Z6002-08 CA6003 (1903) CA6003 446N H6067R CA6003 H6009N (Z8013) CA6023 CA6003 (Z8013) Z6002-07 CA6005 (Z8007) Z6002-08 CA6003 CA6003 96885 (1903) CA6004 CA6003 CA6002 96885 CA6001 (CA6009) CA6011 H6067R CA6007 (Z8015) BS16 CA6001 CA6006 (96882) CA6004 CA6001...
  • Page 42 < EXPLODED VIEW (2) > CA6074 CA6020 CA6018 (H6067R) CA6020 (Z8013) CA6020 CA6074 (96883) CA6018 CA6019 CA6018 CA6020 CA6020 CA6018 (96894) CA6074 CA6019 (96888) CA6020 CA6018 CA6019 CA6020 (96894) CA6020 (96883) CA6074 CA6018 CA6074 CA6021 (96888) CA6019 CA6019 CA6057 CA6021 CA6059 (96893) CA6059...
  • Page 43 < EXPLODED VIEW (3) > CA6039 CA6025 CA6024 CA6026 (96892) CA6038 CA6026 CA6038 CA6026 (96892) CA6036 CA6029 (96891) CA6027 CA6036 (96890) CA6036 CA6028 CA6010 CA6028 CA6036 CA6030 (96891) CA6037 CA6012 CA6030 CA6022 CA6065 CA6065 CA6032 CA6031 CA6031 CA6065 (96888) CA6031 CA6031 (96888) CA6033...
  • Page 44 < EXPLODED VIEW (4) > H6053G 260G H6054 H6055 Z8007 CA6041 1901 CA6045 1901 CA6040 (H3048) 96881 96881 H6054 96881 H6055 CA6041 CA6046 (H3048) 96884 CA6040 CA6043 CA6042 CA6039 96881 CA6042 96884 (96887) CA6047 CA6050 (96881) CA6044 (96887) CA6071 CA6042 CA6049 CA6050 CA6054...
  • Page 45 < EXPLODED VIEW (5) > CA6052 CA6068 CA6052 CA6052 CA6075 CA6067 CA6052 CA6068 CA6068 CA6068 CA6070 CA6067 CA6068 CA6068 CA6070 CA6055 CA6069 CA6070 (CA6055) CA6070 (CA6055) CA6055 CA6055 CA6070 CA6069 (CA6055) CA6070 (CA6055) CA6072 CA6055 CA6055 CA6055 CA6055 CA6072 CA6055 CA6073...

  • Page 46: Spare Parts

    703 x 1 2000 Cooling Fan Holder CALIBER 60 Body Decal CA6033 1000 CA6073 1000 Cooling Fan Cover CALIBER 60 Tail Fin Decal CA6034 692 x 4 CA6074 631 618 720 x 1 713 x 2 3000 Servo Linkage Drive Belt Tensioner...

  • Page 47: Optional Parts

    Clutch Wrench HP6mmHexagon Reversible Shaft (YS) CA6076 H3220 1500 Clutch Shaft (YS) Coloured Tracking Tape CA6501 1791 2500 6800 CALIBER 60 Frame Stay Blitz Starter 45000 CA6502 2161 3200 CALIBER 60 Flapping Head Blade Balancer 39308 CA6503 2800 1000 Fuel Filter(M) Spindle Shaft (Coning 1 deg.)
  • Page 48 SCREW NUT etc. ¯ QUANTITY Round Head Screw 1101 2x6 2x8 2x10 2x15 5 each 1132 2x4 2x6 2x8 2x10 5 each 1171 2mm 2.6mm 10 each 1102 2.6x8 2.6x10 2.6x12 2.6x14 5 each 1133 2.6x6 2.6x8 2.6x10 2.6x12 5 each 1172 3mm 4mm 10 each...

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