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Synergy NSC CONTENDER Instruction Manual

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Summary of Contents for Synergy NSC CONTENDER

  • Page 2 Congratulations on your purchase of the Synergy N5c radio controlled helicopter kit. The Synergy N5c was designed and developed by Botos Design & Distribution Inc.. The design of the Synergy N5c 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.
  • Page 3 TABLE OF CONTENTS Fuel Tank Assembly Torque Tube Assembly Landing Gear Assembly Tail Boom to Torque Tube Assembly Engine / Clutch Assembly Torque Tube Tail Section Completion Clutch Bell & Start Shaft Assembly Torque Tube Input Transmission Assembly Servo Tray Assembly Input Transmission Installation Right Frame Support Assembly Tail Boom Install...

  • Page 4: Tools Required For Assembly

    Tools Required For Assembly • Needle Nose Pliers • Diagonal Cutting Pliers • Phillips Screw Driver Set • Hex Drivers 1.5/2/2.5/3 • Scissors • Grease • CA Glue • Loctite - Blue & Red • JB Weld • Metric Ruler •...

  • Page 5: Fuel Tank Assembly

    Fuel Tank Assembly 610-330 Fuel Tank Trim fuel tubing to 65mm or desired length so that fuel clunk reaches to the rear of fuel tank. 110-333 Fuel Clunk Tubing Complete Fuel Tank 110-332 Fuel Clunk 106-810 Fuel Tank Stopper Grommet 110-331 Fuel Tank Stopper...

  • Page 6: Landing Gear Assembly

    Landing Gear Assembly 610-322 Skid Tube Lock x4 610-324 Landing Gear Strut 610-321 Skid Tube Screw Skid Tube Lock Down on to flybar then secure within Skid Tube 101-308 M3x8 Button Head 106-966 Skid Tube Plug x4 Complete Landing Gear...
  • Page 7 Engine Clutch Assembly 108-110 8x12x12 One Way Clutch (Factory Installed) 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 M4x8 Socket Head x2 finish tightening engine nut.
  • Page 8 Clutch Bell & Start Shaft Assembly 100-466 M4x6 Set Screw 106-955 Hex Adapter 106-326 26mm Hex Standoff x2 108-615 6x15x5 Radial Bearing 610-120 20T Pinion Gear 110-155 Clutch Bearing Block Factory Installed 108-105 10x19x5 Radial Bearing x2 108-614 6x12x4 Radial Bearing Factory Installed 610-125 Clutch Bell, Lite Install governor magnet before assembly...
  • Page 9 Servo Tray Module Assembly Servo Screw(included with servo) 100-212 M2x12 Socket Head x12 106-326 26mm Hex Stand off 610-210 Servo Tray Module 100-252 M2 Nylock Nut x6 Pivot Ball Mount Distance For optimal performance pivot balls should be mounted between 13.5mm from the center of the servo.
  • Page 10 Right Frame Support Installation 610-124 N5C Front Frame Spacer 610-123 Tail Servo Mount 120-122 Anti-Rotation Guide Large Flange oriented on outside of frame 100-266 M2.5x6 Socket Head 610-223 3x26 Threaded Spacer 108-484 4x8x3 Flange Bearing Do not over tighten in plastic 101-308 M3x8 Button Head 100-376 M3x16 Set Screw 100-306 M3x6 Socket Head...
  • Page 11 Bearing Block Assembly & Installation 510-542 Main Shaft Bearing Block, Lite 108-106 10x19x6 Radial Bearing 108-819 8x19x6 Radial Bearing 510-542 Main Shaft Bearing Block, Lite 100-308 M3x8 Socket Head DO NOT FULLY TIGHTEN THESE BOLTS YET!
  • Page 12 Servo Tray Installation 100-306 M3x6 Socket Head Do not fully tighten screws!
  • Page 13 Clutch Bell & Belt Idler Installation Belt Idler Assembly Belt Idler for Belt Drive System Only 108-384 3x8x4 Radial Bearing 610-318 Belt Tension Idler 109-352 3x5x2 Brass Spacer 100-320 M3x20 Socket Head 108-384 3x8x4 Radial Bearing 101-306 M3x6 Button Head 100-310 M3x10 Socket Head 610-319 Idler Brace 106-930 M3 Step Washer...
  • Page 14 Left Frame Side Assembly Step #1 108-484 4x8x3 Flanged Bearing Install Bearing Flange to outside of frame 610-311 Main Frame 610-122 Throttle Servo Mount 610-317 Idler mount Block 101-306 M3x6 Button Head 100-206 M2x6 Socket Head 100-310 M3x10 Socket Head 100-310 M3x10 Socket Head 610-323 Landing Gear Mount Block...
  • Page 15 Left Frame Assembly Step #2 Do not over tighten in plastic 101-308 M3x8 Button Head 100-376 M3x16 Set Screw 100-308 M3x8 Socket Head Do not tighten bolts completely 100-306 M3x6 Socket Head until next step. 100-354 M3 Washer 610-422 Canopy Stand Off 100-306 M3x6 Socket Head 100-320 M3x20 Socket Head Belt Idler Assembly...
  • Page 16 Frame Alignment With all bolts slightly loose, place frameset on a flat surface. Slide main shaft into main shaft bearing blocks to make sure the main shaft spins freely. Be sure that side frames are 90 degrees to the flat surface. Once you have achieved the correct frame alignment you may finish tightening frame bolts.
  • Page 17 Landing Gear & Fuel Tank Installation 106-807 Tank Edge Grommet Fuel Tank Assembly 110-419 Fuel Tubing Grommet, Frame Landing Gear Assembly 100-316 M3x16 Socket Head...

  • Page 18: Engine Installation

    Engine Installation Note - Ensure engine is vertically aligned with clutch stack. Start shaft should rotate freely, and bottom of clutch should be parallel with bottom of clutch bell. 606-305 Motor Spacer 50-55 Sized Motor M3x12 Socket Head 610-126 Motor Mount, Lite...
  • Page 19 Fan Shroud Installation 610-224 3x6x26 Threaded Frame Spacer 100-312 M3x12 Socket Head 610-342 Fan Shroud Right 100-312 M3X12 Socket Head 100-210 M2x10 Socket Head Do not over tighten! 610-343 Fan Shroud Left...
  • Page 20 108-483 4x8x3 Radial Bearing Bell Crank Assembly 107-106 Short Pivot Ball Note orientation of boss before assembly of pivot 610-222 Outside Elevator Bell Crank ball to bell crank. 610-221Bell Crank (Aileron & Pitch) 100-464 M4x4 Flat Point Set Screw 610-228 Bell Crank Spacer 107-106 Short Pivot Ball 610-225 Bell Crank Shaft 100-464 M4x4 Flat Point Set Screw...
  • Page 21 Cyclic Bell Crank Installation Make sure there is no lateral movement in elevator bell crank assembly. Pinch inside bell crank to outside bell crank then tighten set screws. Note Bell Crank alignment hole in frame for ease of correct setup. 100-464 M3x4 Flat Point Set Screw 101-306 M3x6 Button Head 100-464 M3x4 Flat Point Set Screw...
  • Page 22 Belt Drive Tail Box Assembly 100-351 M3 Nylock Nut Note - If you purchased the N5c with torque tube, proceed to page A20 615-317 Tail Lever Mount Step #2 Tail Box Assembly 615-314 9T Tail Pulley (for 6mm shaft) 106-301 M3 Shim 615-124 Tail Output Shaft 100-251 M2 Nut 108-373 3x7x3 Radial...
  • Page 23 Belt Drive Tail Box Assembly 615-140 Tail Boom 109-357 3x5x7 Brass Spacer 615-316 Belt Tension Idler Do not over tighten belt idler bolt! 100-351 M3 Nylock Nut Over tightening will cause bearings inside idler to bind. 101-306 M3x6 Button Head 108-384 3x8x4 Radial Bearing 108-616 6x13x5 Flange Bearing 109-357 3x5x7 Brass Spacer...
  • Page 24 Tail Hub Assembly DO NOT OVER TIGHTEN! 108-503 5x10x3 Radial Bearing 100-308 M3x8 Socket Head 100-354 M3 Washer 515-525 HD Tail Blade Grip 106-501 5mm Shim 108-511 5x10x4 Thrust Bearing 107-106 Pivot Ball GREASE THRUST BEARING INNER RACE! Tail Thrust Bearing Note - - Large OD / Large ID - Inside - Small OD/ Small ID - Outside - Shim goes between Thrust...
  • Page 25 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 radial bearings do not have lateral load 108-812 8x12x2.5 Radial Bearing on them.
  • Page 26 Tail Pitch Slider & Tail Rotor Hub Installation Note - If you purchased the N5c with torque tube, proceed to page A25 Size Links for free tail slider operation 100-351 M3 Nylock Nut 100-351 M3 Nylock Nut 100-316 M3x16 Socket Head 100-464 M4x4 Set Screw...
  • Page 27 Belt Drive Tail Push Rod & Guides 115-114 Tail Control Guide 615-128 Boom Support Clamp, Lite Slide Tail Control Guide to approx. 265mm from the front of the boom. Place the rear Tail Control Guide behind Boom Support Clamp. 100-310 M3x10 Socket Head 107-100 Ball Link 107-078 78mm Rod 106-965 Tail Push Rod Sleeve...
  • Page 28 Belt Drive Tail Boom Installation Slide belt and boom through main boom clamps until boom is flush with second boom clamp. Secure bolts. 100-308 M3x8 Socket Head 100-351 Nylock Nut 115-112 Main Boom Clamp, Lite 100-308 M3x8 Socket Head 100-335 M3x35 Socket Head...
  • Page 29 Boom Support Assembly 100-330 M3x30 Socket Head x2 610-223 3x26 Spacer 610-121 Boom Support Spacer x2 101-412 M4x12 Button Head x2 100-354 M3 Washer x2 Lightly sand carbon rod, use medium CA to secure boom support end. 115-119 Boom Support End 109-345 3x4x5 Brass Spacer 615-117 Carbon Boom Support Rod...
  • Page 30 Tail Box Assembly for Torque Tube 615-322 Tail Gear Pin 108-121 12x18x4 Radial 615-125 Tail Output Bevel Gear 615-124 Tail Output Shaft 615-126 Tail Input Bevel Gear 100-364 M3x4 Cup Point Set Screw 615-321Output Shaft Sleeve 615-131 Tail Input Bearing Spacer 615-118 Metal Tail Box 615-311 Tail Box Plate 100-306 M3x6 Socket Head...
  • Page 31 Tail Bell Crank Assembly 615-122 Tail Bell Crank Plastic Insert Use CA or Epoxy to secure plastic insert 108-373 Radial Bearing 615-123 Tail Bell Crank, Left 100-252 2mm Nylock Nut 100-351 M3 Nylock Nut 109-355 3x5x5 Spacer 107-104 2mm Pivot Ball 108-373 Radial Bearing 106-301 3mm Shim Do not over tighten!
  • Page 32 Tail Rotor Hub and Tail Pitch Slider Installation (for torque tube) Note direction of tail blade grips! Torque tube tail rotor grips are trailing edge control 100-464 M4x4 Set Screw Ball Links need sizing for smooth operation. We recommend the Boto-Sizer (700-001)
  • Page 33 Torque Tube Assembly Glue radial bearings on to torque tube using CA or Epoxy. See below Use Red or Green Loctite to illustration for spacing. secure torque tube end into torque tube. 108-814 8x14x4 Radial Bearing 615-120 TT Bearing Housing 100-210 M2x10 Bolt 615-127 Torque Tube End 615-129 Torque Tube...
  • Page 34 Tail Boom & Torque Tube Apply synthetic lithium grease to torque tube O-rings to aid with insertion into tail 615-140 Tail Boom boom. 115-114 Tail Push Rod Guide 106-965 Tail Push Rod Sleeve x2 Measure approx. 10mm between ball link and carbon tube.
  • Page 35 Torque Tube Tail Section Completion Slide Boom completely into tail box! We have provided a 3mm tapped hole if you decide that you would like to drill a locating hole in the boom. This is generally not needed but some people feel more comfortable with this configuration.
  • Page 36 Torque Tube Input Transmission Assembly 100-366 M3x6 Cup Point Set Screw 610-135 18T Tail Input Pinion 610-138 TT Coupler Insert 100-364 Cup Point Set Screw 610-139 TT Coupler 100-366 M3x6 Cup Point Set Screw 610-130 Tail Input Shaft 108-614 6x12x4 Radial Bearing 610-137 Input Shaft Bearing Block, Rear 108-614 6x12x4 Radial Bearing 610-134 Input Shaft Bearing Block, Front...
  • Page 37 Input Transmission Installation 615-130 TT Doubler Plate 100-310 M3x10 Socket Head 100-306 M3x6 Socket Head 615-130 TT Doubler Plate 100-310 M3x10 Socket Head 100-306 M3x6 Socket Head...

  • Page 38: Tail Boom Installation

    Tail Boom Installation Slide Tail Boom through boom clamps until edge of tail boom is flush with edge of front boom clamp. Ensure torque tube end aligns and engages with input coupler.
  • Page 39 Main Gear/Auto Hub Assembly 610-147 Auto Hub Sleeve If you purchaced Torque Tube N5c, finish Main Gear Auto Hub, skip Main Belt Pulley Assembly and proceed to page A38. 610-151 Auto Hub Delrin Shim 610-170 170T Main Gear 200-407 Auto Hub Assembly (Factory Assembled) 103-204 M2x4 Type I Cross Recessed 610-143 Main Pulley Flange...
  • Page 40 Main Belt Pulley and Main Gear Installation 610-140 Main Shaft Install main shaft with smalller 8mm end pointing down. 100-261 M2.5x10 Socket Head 610-150 Main Shaft Collar Main Gear Assembly Main Pulley Assembly Twist Belt 1/4 Turn Clockwise.
  • Page 41 Belt Drive Train Install Step #2 Gently push down on main shaft while pressing up on main shaft collar. After tightening main shaft collar ensure there is no vertical play in the main shaft. 100-320A M3x20 Shouldered Socket Head 100-351 M3 Nylock Nut x2 100-325A M3x25 Shouldered Socket Head...
  • Page 42 Crown Gear Assembly Screw Crown Gear Hub Lock Nut on loosely for now. This will 610-132 Crown Gear Hub Lock Nut be tightened later 610-136 Crown Gear 101-208 M2x6 Button Head x8 610-131 Crown Gear Hub...
  • Page 43 Crown & Main Gear Installation 610-140 N5 Main Shaft 100-261 M2.5x10 Socket Head Bolts used for pinching do not need loctite 610-150 Main Shaft Collar Main Gear Assembly and Crown Gear Assembly are inserted into the frames together in this step. After installation, gently press down on Main Shaft while lifting up on Main Shaft Collar and tighten 2.5x10mm Main Shaft Collar bolt.
  • Page 44 Auto Hub Bolt Install Slide Crown Gear Assembly all the way up and install bolt through auto hub lock ring and main shaft. Secure other side with nylock nut. Once complete, slide Crown Gear Assembly back down for next step. DO NOT OVER TIGHTEN! This only needs to be gently tighten.
  • Page 45 Crown Gear Hub Pin Installation 606-924 Crown Gear Hub Pin 1.Align Crown Gear Hub hole with corresponding Main Shaft hole. 2. Insert Crown Gear Hub Pin until flush with Crown Gear Hub 3. Tighten Crown Gear Lock Nut with 17mm or 11/16 in open end wrench. -DO NOT OVER TIGHTEN NUT-...
  • Page 46 Crown Gear Mesh Adjustment Crown Gear mesh may be adjusted by loosening two 18T pinion set screws and sliding pinion fore/aft. Correct mesh is obtained when outer tooth of pinion is aligned with outer tooth of crown gear. 100-364 3x4mm Cup Point Set Screws x2...
  • Page 47 Tail Servo & Linkage Assembly 107-106 Pivot Ball 100-316 M3x16 Socket Head 108-373 3x7x3 Radial 109-352 3x5x2 Spacer 110-225 Tail Offset Bell Crank 108-373 3x7x3 Radial 107-106 Pivot Ball 107-100 Ball Link 106-301 3mm Shim 110-227 274mm Carbon Support Rod 107-100 Ball Link 107-295 295mm Tail Linkage Rod Attention!
  • Page 48 Flybar Rotor Head Assembly THIS STEP FOR FLYBAR HEADS ONLY 100-308 M3x8 Socket Head 107-100 Ball Link 620-123 Flybar 100-365 M3x4 Set Screw 620-115 Head Button 120-121 Flybar Control Arm Stand Off 107-030 30mm Rod 100-364 M3x4 Set Screw 107-100 Ball Link 109-351 3x5x1.6 Brass Spacer 107-106 Pivot Ball Head Block Sub Assembly - Factory Assembled...
  • Page 49 Swashplate and Washout Assembly Flybarless configurations can 109-352 3x5x2 Brass Spacer ignore washout assembly but 620-213 Washout Control Arm still need to assembly swash 108-383 3x8x3 Radial Bearing plate. 108-383 3x8x3 Radial Bearing 100-316 M3x16 Socket Head 107-106 Pivot Ball 106-301 3mm shim 620-210 Washout Hub 106-301 3mm Shim...

  • Page 50: Rotor Head Assembly

    Flybar Blade Grip Assembly 520-511 Main Blade Grip Arm 108-816 8x16x5 Bearing 520-512 Main Blade Grip, Metal Large ID Large OD Apply Thick Grease to Thrust Bearing Small ID Small OD 100-305 M3x5 Socket Head 106-801 8x.5mm Washer 108-816 8x16x5 Bearing 100-308 M3x8 Socket Head DO NOT OVER TIGHTEN 108-817 8x16x5 Thrust Bearing...
  • Page 51 Rotorhead to Swashplate Assembly THIS PAGE FOR FLYBAR CONFIGURATION ONLY 107-100 Ball Link 107-078 78mm Control Rod 107-100 Ball Link...

  • Page 52: Rotor Head Installation

    LINK LENGTH GOOD FOR BOTH FLYBAR AND FLYBARLESS CONFIGURATIONS Rotor Head Installation 107-100 Ball Link M3 Nylock Nut 107-043 43mm Rod 100-320A M3x20 Shouldered Socket Head Ensure bolt travels through both Head Block as well as the hole in 107-100 Ball Link the main shaft.
  • Page 53 Flybarless Head Assembly 100-312 M3x12 Socket Head 620-111 FBL Head Block 120-114 Head Axle 520-514 FBL Main Blade Grip 606-803 Solid Head Damper 106-803 8x.5mm Washer 100-554 M5 Washer 520-513 FBL Blade Grip Arm 108-816 8x16x5 Radial Bearing 106-801 8x1mm Washer Apply Grease 100-306 M3x6 Socket Head Apply Grease...
  • Page 54 Flybarless Head Installation Align Swash Driver paralell with head Pitch Link block. Adjust height of swash driver so washout link is 90 degrees to Washout Arm at zero degrees collective pitch. See illustration below. Correct! Use lowest hole on head block when using stock 78mm pitch links 100-351 M3 Nylock Nut 100-320 M3x20 Socket Head...
  • Page 55 Elevator Linkage 107-100 Ball Link 107-078 78mm Rod 107-100 Ball Link...

  • Page 56: Aileron Linkage

    Aileron Linkage 107-100 Ball Link 107-100 Ball Link 107-126 126mm Rod...
  • Page 57 Pitch Servo Linkage 107-100 Ball Link 107-102 102mm Rod 107-100 Ball Link...

  • Page 58: Throttle Linkage

    Throttle Linkage 107-100 Ball Link 107-102 102mm Rod 107-100 Ball Link 100-212 M2x12 Socket Head...
  • Page 59 Radio Plate Installation Route all wires as you see fit Some radio gear may fit in between frames Install CF Radio Plate Install Radio Gear on CF Radio Plate 103-256 M2.5x6 Counter Sunk Screw 610-314 Carbon Fiber Radio Plate...
  • Page 60 Canopy and Blades 100-435 M4x30 Shouldered Bolt Accepts 600mm - 630mm Blades 100-451 M4 Nylock Nut 110-418 Conopy Gromet 610-404 Fiberglass Canopy Use Medium CA to secure canopy gromets to canopy. 100-316 M3x16 Socket Head 510-425 Canopy Thumb Screw...
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