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Synergy E5 Instruction Manual
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Synergy E5 Instruction Manual

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Summary of Contents for Synergy E5

  • Page 1 w w w . s y n e r g y r c h e li c o p t e r s . c o m...
  • Page 2 w w w . s y n e r g y r c h e li c o p t e r s . c o m...
  • Page 3 Lower Frame Brace Assembly 103-256 M2.5 Flat Head Cross Recess 305-102 CF Lower Frame Brace 103-256 M2.5 Flat Head Cross Recess 305-101 E5 Frame Spacer 305-103 E5 CF Gyro Mount Plate 305-101 E5 Frame Spacer Gyro Mount Plate Assembly Page 1 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 4 Main Shaft Bearing Block Assembly 108-105 - 10x19x5 Radial Bearing *** Note *** Observe orientation of bearing blocks 305-124 E5 Main Shaft Bearing Block 108-105 - 10x19x5 Radial Bearing 305-104 E5 Third Main Shaft Bearing Block Page 2 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 5 101-306 M3x6 Button Head x12 320-118 Front Trans Bevel Gear 320-303 Spur Gear Bottom Bearing Block 108-593 5x9x3 Radial Bearing 305-105 E5 TranSupport Standoff 320-408 Spur Gear Shaft 100-372 M3x12 Set Screw 305-213 13T Spur Gear 320-407 2mm Spur Gear Pin IMPORTANT! - Any screw which is metal to metal needs loctite! Clean oil from bolts and apply blue loctite.
  • Page 6 Key Chain Style Canopy Mounts Front Canopy Mounts (21mm) 305-121 Key Chain Canopy Mount, Female 21mm 305-106 Break-away Plate Rear Canopy Mounts (17mm) 305-106 Break-away Plate 101-306 M3x6 Button Head 305-117 Key Chain Canopy Mount, Female 17mm 101-306 M3x6 Button Head Page 4 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 7 Front Battery Plate 103-256 M2.5 Flat Head Cross Recess 305-107 Front Battery Plate 305-101 E5 Frame Spacer Page 5 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 8 Rear Battery Plate 103-256 M2.5 Flat Head Cross Recess 305-108 E5 Rear Battery Plate 305-101 E5 Frame Spacer Page 6 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 9 ESC Mount Plate 103-256 M2.5 Flat Head Cross Recess 305-109 E5 ESC Mount Plate 305-101 E5 Frame Spacer Page 7 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 10 Main Boom Clamps and Radio Plate 101-306 M3x6 Button Head 305-110 E5 Radio Plate 305-111 E5 Main Boom Clamp 100-310 M3x10 Socket Head Note - Bolts engaged in pinching mechanism do not require loctite Page 8 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 11 ATTENTION! DO NOT FULLY TIGHTEN BOLTS YET!! 100-306 M3x6 Socket Head x8 305-118 E5 Main Frame CF 100-308 M3x8 Socket Head Note - Third Main Shaft Bearing Block is adjustable fore and aft to provide for correct main shaft alignment.
  • Page 12 Battery Plate - Install 101-306 M3x6 Button Head NOTE - DO NOT FULLY TIGHTEN BOLTS YET! Page 10 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 13 Gyro Plate and Lower X Brace - Install NOTE - DO NOT FULLY TIGHTEN BOLTS 101-306 M3x6 Button Head Page 11 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 14 Front Tail Transmission Install NOTE - DO NOT TIGHTEN BOLTS FULLY YET! **IMPORTANT PLEASE READ** Frames are slotted for optional tail gear ratios Tail Transmission was designed to slide fore and aft to allow for 4.0:1 gear ratio 101-306 M3x6 Button Head as well as optional 4.5:1 tail ratio.
  • Page 15 Main Boom Clamp and Radio Plate Install 100-306 M3x6 Socket Head Bolt Page 13 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 16 Tail Servo Mount High Quality Digital 760us Tail Servo (Not Included) Recommended - Futaba BLS256 305-112 Elevator Tail Servo Mount Note - Servo horn will need to be trimmed in order to avoid interference with gyro sensor mount. 100-252 M2 Nylock Nut Important - Pivot ball should be located at 16mm from center of servo horn.
  • Page 17 Tail Servo Install 100-266 M2.5x6 Socket Head Page 15 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 18 Canopy Mount Install - Left Frame Side 305-101 E5 Frame Spacer 101-306 M3x6 Button Head 101-310 M3x10 Button Head 21mm Front Canopy Mount See Page 4 17mm Rear Canopy Mount Assembly See Page 4 100-351 M3 Nylock Nut Note - Button Head fits into large frame hole, mounts will fit flush against frame.
  • Page 19 Right Frame Canopy Mount Install 100-351 M3 Nylock Nut 305-118 E5 Main Frame CF Page 17 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 20 Elevator Servo Mounting 100-266 M2.5x6 Socket Head 100-268 M2.5x8 Socket Head 106-115 Servo Hold Down x2 305-112 Elevator-Tail Servo Mount X2 Page 18 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 21 Right Frame Install - Socket Head Bolts DO NOT TIGHTEN BOLTS YET! 100-306 M3x6 Socket Head 100-308 M3x8 Socket Head Page 19 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 22 Right Frame Install - Button Head Bolts 101-306 M3x6 Button Head Bolt x12 Page 20 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 23 Frame Alignment - Anti Rotation Bracket Install Tighten all frame bolts fully once you are satisfied Use E5 Main Shaft to align bearing blocks with frame alignment. Tighten Anti-Rotation Bracket bolts last. Note - Third bearing block is adjustable fore/aft to allow for better alignment of bearing blocks.
  • Page 24 Landing Gear Mounts 101-306 M3x6 Button Head 305-122 E5 Landing Gear Mount Page 22 WWW.SYNERGYRCHELICOPTERS.COM...

  • Page 25: Landing Gear Assembly

    101-308 M3x8 Button Head 106-966 Skid Tube Plug 610-322 Skid Tube Lock 305-123 E5 Skid Tube Note - Alternatively if you find the Skid Tube Locks too difficult, you can use M4x6 Set Screws to secure the E5 Skid Tube.
  • Page 26 Landing Gear Install 100-312 M3x12 Socket Head x4 Page 24 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 27 Auto Hub Assembly Important - Bronze bushings must be secured with green or red loctite! Auto Hub Bronze Bushing 200-407 - Auto Hub Assembly One Way Clutch Bearing DO NOT USE GREASE ON ONE-WAY!! USE LIGHT OIL SUCH AS TRIFLOW! Auto Hub Auto Hub Bronze Bushing Important - Bronze bushings must be secured...
  • Page 28 Main Gear and Spur Gear Assembly IMPORTANT - PLEASE READ!!! Note - Do not use grease inside 320-410 Spur Gear Hub auto hub assembly. Please use light oil such as Triflow. 305-152 52T Spur Gear 101-308 M3x8 Button Head x4 103-256 M2.5x6 Cross Recess Factory Auto Hub Orientation 305-119 119T Main Gear...
  • Page 29 Main Gear Transmission Installation 305-140 E5 Main Shaft IMPORTANT! Pinch collar has a boss which should be oriented facing down against the inner race of the main shaft bearing. 610-150 Pinch Collar IMPORTANT! - Boss on Jesus bolt collar should be facing 100-261 M2.5x10 Socket Head...
  • Page 30 Motor Pinion Support Bearing Block 108-615 6x15x5 Radial Bearing 305-114 E5 Pinion Support Bearing Block Page 28 WWW.SYNERGYRCHELICOPTERS.COM...

  • Page 31: Motor Mount Assembly

    The Synergy E5 has a 52mm inner frame width and a motor mount that accepts 25mmx3mm or 30mmx4 mount patterns. This means that the E5 is one of the most configurable helicopters on the market today! With parts already available you can also stretch your E5 to accept 600mm rotor blades.

  • Page 32: Motor Installation

    High pressure grease is recommended for smooth operation. 305-115 E5 Motor Mount CF Washer 100-310 M3x10 Socket Head x10 305-116 E5 Pinion Support CF Washer IMPORTANT!- Pinion must rest on lower pinion support radial bearing.
  • Page 33 ESC Mount Plate Install Recommended ESC - ICE2 HV120 Note - 6S Helicopters are low voltage / high current models. Current draw can be very high depending on your configuration. Choose an ESC that is adequate for your configuration. 101-306 M3x6 Button Head x4 Important Tips! - Use quality 60/40 rosin core solder with a high temp soldering iron - Do not allow motor or ESC wires to interfere with carbon frames...

  • Page 34: Torque Tube Assembly

    100-212 M2x12 Socket Head 320-503 Torque Tube Bearing Housing 108-814 8x14x4 Radial Bearing 305-301 E5 Torque Tube Secure bearing to Torque Tube with Red Loctite or CA Bearing must be installed before Torque Tube end as the bearing will not slide over the Torque Tube End.
  • Page 35 Tail Boom Bolt Hole (Optional but highly recommended) Note - Synergy boom clamps have proven to be adequte for securing the tail boom for most helicopter pilots. As an added precaution you may pin the boom with a 3mm bolt.

  • Page 36: Tail Boom Assembly

    Tail Boom Assembly Torque Tube Assembly (Page 32) 305-302 E5 Tail Boom 115-114 Tail Control Guide 100-312 M3x12 Socket Head 610-128 Boom Support Clamp, Lite 115-114 Tail Control Guide Note - CA May be required to secure Tail Control Guide to Tail Boom Page 34 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 37 115-119 Boom Support End applying glue! Top - attaches to boom clamp 115-119 Boom Support End 305-303 E5 Boom Support Rod Notes - 1. Use Epoxy or JBWeld 2. Ensure ends are in alignment while glue sets 109-345 3x4x5 Brass Spacer...
  • Page 38 Tail Boom & Boom Support Install IMPORTANT! DO NOT SLIDE TAIL BOOM FORWARD ANY MORE THAN FLUSH WITH FRONT BOOM CLAMP!! THIS CAN Tail Boom Assembly (page 34) PLACE PRESSURE ON TRANSMISSION GEAR MESH!! 101-306 M3x6 Button Head Optional if hole is drilled 101-410 M4x10 Button Head Boom Support Assembly (page 35) 100-316 M3x16 Socket Head...
  • Page 39 Tail Rotor Hub Assembly IMPORTANT! - Apply Grease to Thrust Bearing Ball Race 108-511 5x10x4 Thrust Bearing Small OD Small ID Ball Race 100-306 M3x6 Socket Head Large ID Large OD 108-503 5x10x3 Radial 100-354 M3 Washer 108-503 5x10x3 Radial 106-501 5mm Shim 515-525 Tail Blade Grip 107-106 Pivot Ball...
  • Page 40 Pitch Slider Assembly 506-920 E-Ring 115-322 Tail Pitch Link 108-812 8x12x2.5 Radial Bearing 115-319 Tail Bearing Ring 106-813 Tail Slider Lock Ring 1. After installing lock ring be sure that the 108-812 8x12x2.5 Radial Bearing radial bearings do not have lateral load on them.
  • Page 41 101-306 M3x6 Button Head 108-124 12x18x4 Radial Bearing 320-405 Tail Box Bearing Spacer 100-366 M3x6 Set Screw 305-618 E5 18T Mushroom Tail Bevel Gear 305-305 E5 Tail Box Plate Left 305-306 Tail Box Plate Right 108-613 6x13x5 Radial Bearing 101-306 M3x6 Button Head...
  • Page 42 Tail Rotor Bell Crank Assembly 100-351 M3 nylock Nut 305-310 E5 Tail Lever Mount 101-308 M3x8 Button Head 100-251 M2 Nut 106-301 M3 Shim 108-373 3x7x3 Radial Bearing 109-355 3x5x5 Brass Spacer Tail Rotor Bell Crank 108-373 3x7x3 Radial Bearing...
  • Page 43 Tail Box Completion Note - Sizing of ball links is recommended for smooth operation. For best results use Boto-Sizer Tool Part #700-001 100-464 M4x4 Set Screw Page 41 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 44 Tail Box Install 101-306 M3x6 Button Head IMPORTANT! If you wish to use boom pinning feature you must drill 3mm hole! Follow these steps. Install Tail Box Ensure Tail Box is vertical Mark drill location Remove tail box and torque tube Drill 3mm hole at marked location Page 42 WWW.SYNERGYRCHELICOPTERS.COM...

  • Page 45: Tail Control Rod Assembly

    Tail Control Rod Assembly Note - Lightly sand carbon tail control rod prior to securing with JB Weld! 305-565 E5 Tail Control Rod 565mm Note - Tail push rod ends will slide through tail control guides. 106-965 Tail Push Rod Sleeve (Teflon)
  • Page 46 Tail Control Rod Install 107-100 Ball Link Note - Adjust ball links so tail rotor bell crank is 90 degrees to tail box while tail servo arm is perfectly vertical. This will automatically configure 5 degree torque compensation at tail rotor blades. WWW.SYNERGYRCHELICOPTERS.COM Page 43B...

  • Page 47: Swash Plate Assembly

    Swash Plate Assembly 107-108 Pivot Ball Long x3 107-106 Pivot Ball x4 100-364 M3x4 Set Screw 108-373 3x7x3 Radial Bearing 200-401 Swash Plate Assembly 100-312 M3x12 Socket Head 100-316 M3x16 Socket Head 109-352 3x5x2 Brass Spacer Page 44 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 48 Head Block and Blade Grip Assembly 305-201 E5 Head Block Important - Apply grease to thrust bearing ball race 305-202 E5 Blade Grip 305-205 E5 Head Axle 606-803 Solid Head Damper 106-803 8x1mm Washer 108-816 8x16x5 Radial Bearing 310-144 Blade Bolt Adapter 4mm...
  • Page 49 Note - Do not tighten 100-323 bolt until the next page. These will pinch and secure the main shaft. 106-301 M3 Shim 108-383 3x8x3 Radial Bearing 305-206 E5 Washout Control Arm 109-352 3x5x2 Brass Spacer 108-383 3x8x3 Radial Bearing 100-323 M3x23 Socket Head 305-207 E5 Ball Link Adapter 100-272 M2.5x12 Set Screw...
  • Page 50 WWW.SYNERGYRCHELICOPTERS.COM Rotor Head Install 100-351 M3 Nylock Nut 100-320A 3x20 Shouldered Bolt IMPORTANT! IMPORTANT! Do not forget to tighten pinch bolts! Do not over tighten 100-320A Bolt! Page 47...
  • Page 51 Pitch Link Assembly 107-100 Ball Link Note - 700-100 Boto-Sizer Tool is highly recommended for smooth linkage operation. 28mm 107-043 43mm Rod Page 48 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 52 Aileron and Pitch Servo Install 106-115 Servo Hold Down 100-261 M2.5x10 Socket Head 106-115 Servo Hold Down Page 49 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 53 Servo Horn Assembly IMPORTANT! - Use Red Loctite to secure Pivot Ball to M3 Nut 100-352 M3 Nut 310-107 CF Servo Arm 107-106 Pivot Ball 100-206 M2x6 Socket head Note - It is best to determine servo horn position clostest to 90 degrees before fixing CF servo arm 100-251 M2 Nut to the servo arm wheel.
  • Page 54 Servo Arm Install Page 51 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 55 WWW.SYNERGYRCHELICOPTERS.COM Servo Horn Alignment Holes Alignment Holes Alignment Holes Page 52...
  • Page 56 Cyclic Link Assembly 107-100 Ball Link 19.30mm 107-043 43mm Rod Page 53 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 57 Rotor Blade Install Rotor Blades Not Included For optimum performance use Rail 556mm rotor blades. 100-435A M4x35 Shouldered Bolt 100-451 M4 Nylock Nut Page 54 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 58 Tail Blade Install Rail 96mm Tail Blade (Not Included) Note - Counter clockwise rotating tail. Install tail blades as illustrated. 305-312 Tail Blade Washers x2 100-351 M3 Nylock Nut 100-316 M3x16 Socket Head 305-312 Tail Blade Washers x2 100-351 M3 Nylock Nut Page 55 WWW.SYNERGYRCHELICOPTERS.COM...

  • Page 59: Canopy Assembly

    Canopy Assembly 305-126 Key Chain Canopy Grommet 305-125 Key Chain Canopy Mount Male Note - Canopy holes may need enlarged to approximately 8-9mm in order to correctly install the canopy rubber grommet. 305-125 Key Chain Canopy Mount Male Page 56 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 60 Synergy E5 - Completed! Page 57 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 61 Main Rotor Diameter 1253.500 Rotor Disk with 556mm blades - 1253.50mm Rotor Disk with 606mm blades - 1353.50mm (configured with E6 boom) Page 58 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 62 Tail Rotor Diameter Page 59 WWW.SYNERGYRCHELICOPTERS.COM...
  • Page 63 Synergy E5 - Dimensions 360mm 1085mm 214mm Page 60 WWW.SYNERGYRCHELICOPTERS.COM...

This manual is also suitable for:

999-308