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Synergy 516 Manual

500 class, 500-520mm main blades, 80-85mm tail blades
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Rev 1.0M

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Summary of Contents for Synergy 516

  • Page 1 Rev 1.0M...

  • Page 2: Specifications

    Congratulations on your purchase of the Synergy 516 radio controlled helicopter kit! The Synergy 516 was designed and developed by Botos Design & Distribution Inc.. The design of the Synergy 516 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...

  • Page 3: Left Frame

    Take care to use correct 100-266 101-306 M2.5x6 Socket Head M3x6 Button Head frame and orientation at this step. The 516-219 Rev 1.0M left frame contains the cut out for the Spring Post 100-274 M2.5 Washer tail servo and mount hole for the spring...

  • Page 4: Right Frame

    101-306 cut out for the tail servo and mount M3x6 Button Head hole for the spring post. 01 | INTRODUCTION 516-202 IMPORTANT: Install battery tray rail as Main Frame Right indicated with the rail slot positioned 02 | FRAME 02 | FRAME near the bottom.
  • Page 5 M2 Washer (2) predictable lifespan, main shaft bearings are secured via threadlocker and pre-assembled. Heat will be 01 | INTRODUCTION required for replacement. Apply 516-203 Main Shaft Bearing Block - Top GREEN threadlocker when 02 | FRAME 02 | FRAME replacing.
  • Page 6 103-256 Rev 1.0M M2.5x6 Flat Head M2.5x6 Flat Head Cross Recess (4) Cross Recess (4) 01 | INTRODUCTION 516-213 516-211 Radio Plate Gyro Sensor Plate CF 02 | FRAME 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM...
  • Page 7 FRAME BOLTS Apply BLUE threadlocker to all frame bolts. Do not fully tighten bolts at this Right step. Rev 1.0M 100-266 M2.5x6 Socket Head 01 | INTRODUCTION 02 | FRAME 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 05 | MAIN DRIVE 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY...

  • Page 8: Frame Alignment

    FRAME ALIGNMENT Place airframe on a true flat surface to verify that frames are square before tightening all frame bolts. Temporarily Rev 1.0M insert the main shaft to verify frame alignment. 01 | INTRODUCTION 02 | FRAME 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 05 | MAIN DRIVE...
  • Page 9 103-256 Rev 1.0M M2.5x6 Flat Head Cross Recess (4) 01 | INTRODUCTION 516-214 ESC Plate 02 | FRAME 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 516-200...
  • Page 10 04 | BELT TENSION ARM 05 | MAIN DRIVE 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY 08 | SETTING BELT TENSION 516-207 Landing Gear Mount (2) 09 | SWASH PLATE 10 | CYCLIC SERVOS 11 | ANTI-ROTATION GUIDE 12 | TAIL SERVO...

  • Page 11: Landing Gear

    TIP: Use CA or 30-minute epoxy to secure skid tube plugs. 305-123 Skid Tube (2) 01 | INTRODUCTION 02 | FRAME 516-208 Landing Gear Strut (2) 03 | LANDING GEAR 03 | LANDING GEAR 04 | BELT TENSION ARM 05 | MAIN DRIVE...
  • Page 12 BELT TENSION ARM IMPORTANT: Remove bolts, pivot ball, and apply BLUE threadlocker where indicated. Rev 1.0M IMPORTANT: Guide Pulley 516-405 with wall guides is the stationary pulley. 101-325 M3x25 Button Head Bolt 01 | INTRODUCTION 101-316 M3x16 Button Head Bolt...
  • Page 13 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY 100-266 M2.5x6 Socket Head (2) 08 | SETTING BELT TENSION 516-413 09 | SWASH PLATE Tail Belt 10 | CYCLIC SERVOS Insert tail belt at this stage of 11 | ANTI-ROTATION GUIDE the build.
  • Page 14 01 | INTRODUCTION threadlocker and do not overtighten 101-308 M3x8 Button Heads in the 02 | FRAME 200-506 main gear. 516 Auto Hub Assembly 03 | LANDING GEAR 04 | BELT TENSION ARM 516-302 14x23x2mm Bronze Bushing 05 | MAIN DRIVE...
  • Page 15 M2x4 Type I Cross 01 | INTRODUCTION Recessed (16) 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 516-391 Main Pulley Flange 05 | MAIN DRIVE 05 | MAIN DRIVE 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY...

  • Page 16: Main Drive Assembly

    BD-001 for optimal performance. TIP: Lubricate the Auto Hub Sleeve 01 | INTRODUCTION OIL SLEEVE and one-way bearing with Tri-Flow or 516-301 Auto Hub Sleeve equivalent light machine oil. Do not use 02 | FRAME grease. 03 | LANDING GEAR...
  • Page 17 12 | TAIL SERVO 603MM. 13 | MAIN HEAD Example configurations: Rail 516 Mains + Rail 80.6 Tails = 14 | PITCH LINKAGES 596.6mm. 15 | MOTOR INSTALLATION 520 Mains + Rail 80.6 Tails = 600.6mm.

  • Page 18: Boom Installation

    03 | LANDING GEAR Do not overtighten Tail Control Clamp M2 bolt! 04 | BELT TENSION ARM 05 | MAIN DRIVE 516-401 Tail Boom - 578mm 06 | BOOM INSTALLATION 06 | BOOM INSTALLATION 100-310 M3x10 Socket Head (2)
  • Page 19 TIP: CA may be used to secure Bell Rev 1.0M Crank Insert Guide. 100-351 M3 nylock Nut 01 | INTRODUCTION 02 | FRAME 516-408 Tail Lever Mount 03 | LANDING GEAR 04 | BELT TENSION ARM 108-373 3x7x3 Radial Bearing 05 | MAIN DRIVE...
  • Page 20 TAIL - RIGHT SIDE Apply BLUE threadlocker where indicated. Rev 1.0M 516-402 Tail Box 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR 516-406 Tail Box Plate Spacer 04 | BELT TENSION ARM 05 | MAIN DRIVE 101-306 M3x6 Button Head...
  • Page 21 03 | LANDING GEAR head speeds 2,300 RPM or greater. 04 | BELT TENSION ARM 2,200 RPM or Less: Synergy offers an optional tail pulley 05 | MAIN DRIVE 516-407 (18T) to increase the speed of the tail Tail Output Shaft rotor if desired.
  • Page 22 03 | LANDING GEAR 101-308 rotates counter-clockwise when viewed M3x8 Button Head from the right, while the main rotor 04 | BELT TENSION ARM rotates clockwise when viewed from 516-409 Vert Tail Fin above. 05 | MAIN DRIVE 101-306 M3x6 Button Head 516-404...
  • Page 23 01 | INTRODUCTION 109-311 3x5x11.6 Spacer 108-383 02 | FRAME 3x8x3 Radial Bearing 109-353 3x5x2.8 Brass Spacer 03 | LANDING GEAR 516-405 Tail Guide Pulley 108-383 04 | BELT TENSION ARM 3x8x3 Radial Bearing 109-311 3x5x11.6 Spacer 05 | MAIN DRIVE 100-351...

  • Page 24: Tail - Pitch Slider

    TAIL - PITCH SLIDER IMPORTANT: Disassemble and apply a small amount of threadlocker to the brass sleeve and tighten gently. DO 320-320 Rev 1.0M NOT OVERTIGHTEN or damage can Tail Pitch Slider Threaded occur. 108-812 8x12x2.5 Radial Bearing 320-319 Tail Bearing Ring Aluminum IMPORTANT: Brass sleeve is REVERSE 01 | INTRODUCTION 109-813...
  • Page 25 TAIL - HUB AND GRIPS TIP: Use extreme pressure synthetic grease on all thrust bearings for optimal performance. Boto-Lube Part BD-001 Rev 1.0M IMPORTANT: Full disassembly is 107-106 Pivot Ball required. Apply threadlocker to NOT 107-110 both tail grip pivot balls and bolts. 01 | INTRODUCTION IMPORTANT: Apply threadlocker 02 | FRAME...
  • Page 26 TAIL - FINAL ASSEMBLY IMPORTANT: Secure tail hub set screw using threadlocker. Rev 1.0M For optimal performance, apply light machine oil to the tail shaft. 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 05 | MAIN DRIVE 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY...
  • Page 27 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 90° 05 | MAIN DRIVE 06 | BOOM INSTALLATION 516-223 Tension Spring 07 | TAIL ASSEMBLY 08 | SETTING BELT TENSION 08 | SETTING BELT TENSION 09 | SWASH PLATE...

  • Page 28: Swash Plate

    01 | INTRODUCTION swash pivot balls. Heat may be required for removal. 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 516-108 Inner Swash Plate Top 05 | MAIN DRIVE 766-212 Swash Spherical Ball 10mm 06 | BOOM INSTALLATION...
  • Page 29 Turnbuckle Link Rod 28mm (3) length may vary slightly per individual 02 | FRAME model. 107-099 107-110 516 Plastic Link (6) Pivot Ball 2.5mm x 4.5mm (3) 03 | LANDING GEAR For optimal geometry, all servo linkages should be equal in length.

  • Page 30: Cyclic Servo Installation

    CYCLIC SERVO INSTALLATION Synergy does not supply with the kit: Servos, servo horns, and servo horn bolts. 100-268 Rev 1.0M M2.5x8 Socket Head Apply BLUE threadlocker where indicated. 100-274 M2.5 Washer 01 | INTRODUCTION Use care when configuring the flybarless controller to verify servo 02 | FRAME arms are near or at 90 degrees.
  • Page 31 03 | LANDING GEAR 100-266 04 | BELT TENSION ARM M2.5x6 Socket Head (2) 05 | MAIN DRIVE 516-209 516 Anti-Rotation Brace 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY 516-210 516 Anti-Rotation Mount 08 | SETTING BELT TENSION 09 | SWASH PLATE...

  • Page 32: Tail Servo Installation

    M2.5 Standard Nut recommended for optimal tail geometry and throws. 107-110 Pivot Ball 90° 2.5mm x 4.5mm (3) 01 | INTRODUCTION Synergy does not supply with the kit: servos, servo horns, and servo horn 02 | FRAME bolts. 13.5mm Apply BLUE threadlocker 03 | LANDING GEAR where indicated.

  • Page 33: Tail Control Rod

    107-099 rod with 400 grit sandpaper before Plastic Link applying epoxy. Use 30-Minute or Rev 1.0M 516-411 longer curing Epoxy. Quick or 5-Minute Tail Push Rod End 2mm Epoxy is not recommended. TIP: Insert tail control rod into the 01 | INTRODUCTION...
  • Page 34 08 | SETTING BELT TENSION 09 | SWASH PLATE 100-308 M3x8 Socket Head 10 | CYCLIC SERVOS 100-305 M3x5 Socket Head 516-101 11 | ANTI-ROTATION GUIDE DO NOT OVERTIGHTEN! Main Blade Grip 516-102 12 | TAIL SERVO Pitch Arm 310-144...
  • Page 35 GREASE COMPONENTS 606-803 Rev 1.0M Solid Head Damper 516-100 Head Block IMPORTANT: Apply threadlocker to inside threads of the Head Axle 516-103 Head Axle rather than the Socket Head bolt.
  • Page 36 Bearing (4) Ball Link Adapter Do not overtighten. Apply BLUE 03 | LANDING GEAR threadlocker. 04 | BELT TENSION ARM 516-105 Anti-Rotation Arm 05 | MAIN DRIVE 109-352 3x5x2 Brass Spacer (2) 06 | BOOM INSTALLATION 100-272 M2.5x12 Set Screw...
  • Page 37 PITCH LINKAGES Turnbuckle linkages have reverse threads on one end. 26 mm length is not final, rather a starting point. The final Rev 1.0M length may vary. TIP: Adjust turnbuckles to achieve 01 | INTRODUCTION proper blade tracking. 107-099 02 | FRAME Plastic Link (4) Recommended collective pitch range: +/- 12-15 degrees.
  • Page 38 31mm to engage support bearing. 15 | MOTOR INSTALLATION 15 | MOTOR INSTALLATION OPTIONAL COMPONENTS 16 | BATTERY TRAY & CANOPY 516-016 - 16t Pinion 516-017 - 17t Pinion 17 | BLADE INSTALLATION 516-019 - 19t Pinion 516-020 - 20t Pinion...
  • Page 39 IMPORTANT: Remove and apply 01 | INTRODUCTION BLUE threadlocker to BATTERY LOCK HANDLE. 02 | FRAME 03 | LANDING GEAR 516-216 Battery Plate CF 04 | BELT TENSION ARM 05 | MAIN DRIVE 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY 200-420...

  • Page 40: Blade Installation

    BLADE INSTALLATION Synergy does not include blades in the kit. 100-351 Rev 1.0M 80.6mm Rail tail blades and 516mm Rail M3 Nylock Nut (2) main blades are recommended. 106-804 Tail Blade Washer (4) 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR...
  • Page 41 COMPLETE MODEL Rev 1.0M 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 05 | MAIN DRIVE 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY 08 | SETTING BELT TENSION 09 | SWASH PLATE 10 | CYCLIC SERVOS 11 | ANTI-ROTATION GUIDE 12 | TAIL SERVO...

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