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Bergen INTREPID GAS Owner's Manual

Bergen r/c helicopters
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  • Page 2: Engine Break-In

    There are two more adjustments to make on your new Intrepid. These are the tail rotor and the throttle. With the radio turned on and the tail rotor in neutral (if you have tail compensation turned on, make sure that the collective is also in neutral), position the tail rotor servo arm one spline ahead of the position that would have the ball vertically positioned.
  • Page 3 FINAL ADJUSTMENTS The two aileron pushrods should be adjusted so that with no control input, the rear- most balls on the bell cranks are positioned directly over the pivot point for the transverse lever. This will place the horizontal arms on these bell cranks parallel with the collective levers.
  • Page 4 62. Canopy Bag# Part# Description 1921 Canopy - Lexan 1945 Canopy Grommet 1946 Thumb Screws If canopy is to be painted on the inside, leave the blue plastic coating on the outside of the canopy halves until finished painting. This will add protection should any overspray get on the outside of the canopy.
  • Page 5 CANOPY...
  • Page 6 Cut a piece of fuel tubing about 4 3/8” long. Push one end onto the clunk. Push the other end on the Double End Fitting, on the non-threaded end. This length is approximate, as the final length may need adjusting slightly to get proper clunk operation. Insert the Double End Fitting into the center hole in the tank, from the inside.

  • Page 7: Fuel Tank

    FUEL TANK Overflow Vent Fuel Return Fuel Tank Pickup Fuel Pump Return Fuel Inlet 61. Fuel Tank Bag# Part# Description 1880 Fuel Tank 1850 Clunk 1855 Single End Fitting 1860 Double End Fitting 1865 Fuel Tank Nuts 1870 Fuel Tubing Drill (3) 3/16”...
  • Page 8 FINS 60. Fins Bag# Part# Description 1665 2 Sets Tailboom Clamps MISC. 5010 M3x8 SHCS MISC. 5050 M3x35 SHCS MISC. 5105 M3 Locknuts 1832 Vertical Fin 1835 Horizontal Fin Attach the horizontal fin to the fin clamp that was previously installed onto the tailboom. Use (2) M3x8 SHCS.
  • Page 9 Let cure overnight. There is a push-pull rudder servo upgrade that completes the push-pull control system offered by Bergen R/C. It includes a dual ball bearing supported arm that transfers the servo loads to the arm. Contact your dealer or Bergen R/C Helicopters for more information.

  • Page 10: Rudder Pushrod

    RUDDER PUSHROD 59. Rudder Pushrod Bag# Part# Description Push Rod Carbon Fiber 1983 Pushrod Ends 1956 Ball Link 2.5 5030 M3x16 SHCS 5105 M3 Locknut Push (1) M3x16 SHCS through the open end of (1) Pushrod End. Screw (1) M3 Locknut onto the threaded end sticking out until tight.

  • Page 11: Tailboom Support Struts

    TAILBOOM SUPPORT STRUTS 58. Tailboom Support Struts Bag# Part# Description 1710 Tailboom Support Struts 1715 Tailboom Support Strut Ends MISC. 5015 M3x10 SHCS MISC. 5050 M3x35 SHCS MISC. 5105 M3 Locknuts Temporarily insert the (4) support strut ends into the (2) tailboom support struts. Mount one end of each of the support struts onto the bottom of the fin clamp using a M3x35 SHCS and a M3 locknut.
  • Page 12 Put another M2 nut on the backside of the arm on the screw. Use threadlocker, sparingly. There is a push-pull rudder upgrade available. It consists of a ball bearing push-pull arm and all the hardware necessary to upgrade the machine to a full push-pull control system. Contact your local Bergen R/C dealer for details.

  • Page 13: Rudder Servo

    RUDDER SERVO 57. Rudder Servo Bag# Part# Description 1947 Plastic Servo Mount Tabs 5137 M2x5 Ball 5207 M2x10 PHSMS 5120 M2 Nut Prepare the servo with the hardware provided with the radio system: install the rubber grommets on the servo mounting ears, and then install the brass eyelets into the grommets up from the bottom of the servo ear.

  • Page 14: Tail Blades

    TAIL BLADES 56. Tail Blades Bag# Part# Description 231B Blade Grip Spacer 5146 M3x19 w/11 Shoulder SHCS 5105 M3 Locknut MISC. 6015 Tail Rotor Blades Mount (2) tail blades to blade grips using (4) blade grip spacers, 2 M3 X 19 shoulder SHCS and (2) M3 nylon locknuts.
  • Page 15 PITCH BELLCRANK Trim Here 55. Pitch Bellcrank Bag# Part# Description 240B Bellcrank 240A Delrin Insert 240C Aluminum Spacer 3086 3x7x3 Flanged Bearing 5140 M3x16 w/6 Shoulder SHCS 5155 M3 Brass Washer 5190 Short Ball 5105 M3 Locknut Position the Bellcrank as shown in the first picture. Screw the short ball into the 2 hole facing down.
  • Page 16 Attach each pivot plate arm eyelet and ball link onto each tail blade grip pivot arm using a pivot plate shoulder bolt. The eyelet and ball link should go on the side of the arm facing the center of the tail rotor main hub. Use threadlocker. Slide the tail rotor main hub assembly onto the tail output shaft.

  • Page 17: Tail Pitch Assembly

    TAIL PITCH ASSEMBLY 54. Tail Pitch Assembly Bag# Part# Description 1960 Tail Pitch Slider 5137 M5x2 Ball 5076 M2x8 SHCS 5120 M2 Nut 1961 Tail Special Ball Links 1806 Pivot Plate Arm Eyelet 1811 Pivot Plate Shoulder Bolt 4x4 5195 Medium Ball 5094 M3x4 Set Screw...

  • Page 18: Tail Rotor Grips

    TAIL ROTOR GRIPS 53. Tail Rotor Grips Bag# Part# Description Tail Rotor Blade Grip Assembly 3052 5x10x4 Thrust Bearing 5112 M10 OD Spacer 5110 M3 Flat Washer 5015 M3x10 SHCS 1815 Tail Rotor Main Hub M5 The thrust bearing installs into the tail rotor blade grip assembly as follows: Note: Each of these parts should be liberally greased with a high quality bearing grease before assembly.

  • Page 19: Washout Arm Links

    WASHOUT ARM LINKS Washout Arm Link 52. Washout Arm Links Bag# Part# Description 1956 Ball link 2.5 1995 Collective Linkage 30mm Thread (2) ball links onto the pitch linkage. Thread them on equally. The final length of the link assembly will be 52mm from end – to – end, or 44mm from ball center –...

  • Page 20: Bell Pushrods

    BELL PUSHRODS Bell Pushrod 51. Bell Pushrods Bag# Part# Description 1956 Ball link 2.5 2020 Pitch Linkage 75mm Thread (2) ball links onto the pitch linkage. Thread them on equally. The final length of the link assembly will be 102mm from end – to – end, or 94mm from ball center –...

  • Page 21: Hiller Pushrods

    HILLER PUSHRODS Hiller Pushrod 50. Hiller Pushrod Bag# Part# Description 1956 Ball Link 2.5mm 2025 Flybar Linkage Short 14mm Trim (4) Ball links to a length of 17mm from end to end. Thread (2) trimmed ball links onto (1) short flybar linkage – 14mm. Thread them on evenly so they share equal lengths of the linkage.

  • Page 22: Head Attachment

    HEAD ATTACHMENT 49. Head Attachment Bag# Part# Description 5035 M3x20 SHCS Place aluminum head block atop the main shaft. Align the follower pins in the slots in the head block. Align the hole in the head block above the slot with the hole in the end of the main shaft. Insert M3x20 SHCS and tighten.
  • Page 23 FLYBAR 48. Flybar Bag# Part# Description 1711 Flybar 1175 Flybar Control Arm 5095 M3x4 Set Screw 1165 M4 Special Flybar Arm Washer 1181 Flybar Paddle V Insert Flybar into seesaw. Place (1) M4 special flybar arm washer on each side followed by a Flybar control arm with ball leading for clockwise rotation, viewed from the top.

  • Page 24: Blade Grip Attachment

    BLADE GRIP ATTACHMENT 47. Blade Grip Attachment Bag# Part# Description 3006 8X16X5 Thrust Bearing 1140 M8x.015 Shim Dampening Washer 1145 M4x.008 Shim Dampening Washer 1147 M8x13x1 Shim Dampening Washer 1148 M10x16x1 Washer 5072 M5x16 SHCS 5111 5x10x2 Spacer Washer Place dampening washers on each side of head axle (Thin for soft damping, thick for medium, both for stiff) followed by (1) M8x13x1 washer also on each side.

  • Page 25: Blade Grip Assembly

    BLADE GRIP ASSEMBLY 46. Blade Grip Assembly Bag# Part# Description 1152 Bell Mixer Arm - Delrin 3086 3x7x3F Bearing 5190 Short Ball 5155 M3 Brass Washer 5136 M3x12 w/6mm Shoulder SHCS 5115 M3 Nut 1111 Blade Grip Assembly W/ Bearings Installed 1126 Blade Grip Pitch Arm 5005...
  • Page 26 45. Head Axle Bag# Part# Description 1160 Seesaw End Cap 1130 Head Axle 1135 Dampening O-ring 5095 M3x4 Set Screw 5190 Short Ball 5030 M3x20 SHCS Slide on and fasten the (2) seesaw end caps with (2) M3x4 set screws with removable thread locker, into the groove.
  • Page 27 HEAD BLOCK 44. Head Block Bag# Part# Description 1105 Head Block 3015 3x10x4 Bearing 5155 M3 Brass Washer 5205 M3x5 Philips Pan Head Screw 5010 M3x8 SHCS Place the seesaw assembly in the head block with the groove on the ends of the tube trailing as the head turns clockwise from the top.

  • Page 28: Seesaw Tube Assembly

    SEESAW TUBE ASSEMBLY 43. Seesaw Tub Assembly Bag# Part# Description 1155 Seesaw Tube 3020 4x10x4 Bearing Press a 4x10x4 bearing into each end of the seesaw tube. Be sure that the bearings are flush with the end of the tube. Be sure that the bearings don’t get cocked off line when pressing them in, or damage to the bearings and the seesaw tube will result.
  • Page 29 Align the hole in the radius link with the hole in the back of the washout mixing arm. Press (1) radius link pin into each arm. Use a vise if necessary to press it in. Screw (1) M3x4 set screw into the back end of each arm. This will retain the pin. Use threadlocker.

  • Page 30: Washout Assembly

    WASHOUT ASSEMBLY 42. Washout Assembly Bag# Part# Description 1185 Washout Hub Assembly 1201 Washout Mixing Arm 3086 3x7x3F Bearing 5140 M3x16 Special SHCS 5155 M3 Brass Washer 5095 M3x4 Set Screw 1205 Radius Link 2120 Radius Link Pin 5190 Short Ball Screw (1) short ball into each washout mixing arm.
  • Page 31 There is an elevator yoke upgrade option available. It consists of a larger elevator yoke and two bearing supported vertical A-type arms to link to the swashplate. The anti-rotation bracket is eliminated and more fluid elevator movement and control is the result. The friction of the anti-rotation bracket and the anti-rotation assembly is eliminated.

  • Page 32: Lower Swashplate Linkages

    LOWER SWASHPLATE LINKAGES 40. Lower Swashplate Linkages Bag# Part# Description 1956 Ball Link 2.5 2010 Swashplate linkage 40mm Thread (2) ball links onto the pitch linkage. Thread them on equally. The final length of the link assembly will be 67mm from end – to – end, or 59mm from ball center –...
  • Page 33 SWASHPLATE 39. Swashplate Bag# Part# Description 1215 Swashplate Assembly 5210 Swashplate Anti-Rotation Assembly 5195 Medium Ball 5190 Short Ball Make an anti-rotation assembly by slipping the nylon spacer on (1) M3x20 SHCS followed by (1) M3 hex nut (lightly tightened), (1) brass standoff (tapered side towards ball), and (1) M5x2 threaded ball and another brass standoff (tapered side towards ball).
  • Page 34 Put another M2 nut on the backside of the arm on the screw. Use threadlocker, sparingly. Put the ball on the Philips screw, followed by a M2 nut. Use threadlocker, but sparingly. If the throttle arm is threaded for ball attachment, thread in the Philips screw so the ball faces out when attached to the engine.

  • Page 35: Throttle Linkage

    THROTTLE LINKAGE 38. Throttle Linkage Bag# Part# Description 5137 M2x5 Ball 5207 M2x10 PHSMS 5120 M2 Nut 1980 Throttle Linkage 140mm 1956 Ball Link 2.5 Determine which arm of the servo will point straight down at half throttle. Power the servo with the radio system and set the throttle ATV settings at 100% for each side of half stick.
  • Page 36 Thread (2) ball links onto the pitch linkage. Thread them on equally. The final length of the link assembly will be 152mm from end – to – end, or 144mm from ball center – to – ball center. Make (1) more linkage assembly. Make it the same size as the first one. Snap one end of first link assembly onto the outer right-hand short ball on the elevator xarm.

  • Page 37: Elevator Servo And Pushrods

    ELEVATOR SERVO AND PUSHRODS Trim here if necessary 37. Elevator Servo and Pushrods Bag# Part# Description 5137 M5x2 Ball 5207 M2x10 Philips Screw 5120 M2 Nut 1956 Ball Link 2.5 1985 Elevator Linkage 130mm Power the servo using the radio system. Set the elevator ATV settings at 100% on each side of center stick.

  • Page 38: Elevator Pushrods

    ELEVATOR PUSHRODS 36. Elevator Pushrods Bag# Part# Description 1956 Ball Link 2.5 1990 Elevator Linkage 50mm Thread (2) ball links onto the pitch linkage. Thread them on equally. The final length of the link assembly will be 78mm from end – to – end, or 70mm from ball center –...

  • Page 39: Secondary Collective Pushrods

    SECONDARY COLLECTIVE PUSHRODS 35. Secondary Collective Pushrods Bag# Part# Description 1956 Ball Link 2.5 2000 Collective Linkage 50mm Thread (2) ball links onto the pitch linkage. Thread them on equally. The final length of the link assembly will be 78mm from end – to – end, or 70mm from ball center –...

  • Page 40: Primary Collective Pushrods

    PRIMARY COLLECTIVE PUSHRODS 34. Primary Collective Pushrods Bag# Part# Description 1956 Ball Link 2.5 1995 Collective Linkage 30mm Thread (2) ball links onto the pitch linkage. Thread them on equally. The final length of the link assembly will be 58mm from end – to – end, or 50mm from ball center –...

  • Page 41: Collective Servo Wheel

    COLLECTIVE SERVO WHEEL 33. Collective Servo Wheel Bag# Part# Description 5137 M2x5 Ball 5207 M2x10 Philips Screw 5120 M2 Nut Prepare the Servo output arm (disc) by drilling as shown in the diagram. These are the correct dimensions for a Futaba 9202 servo. Use a 2mm drill. Collective Servo disk ball locations should be identical to primary bell crank ball locations.

  • Page 42: Aileron Pushrods

    AILERON PUSHRODS 32. Aileron Pushrods Bag# Part# Description 1956 Ball Link 2.5 2005 Aileron Linkage 85mm Thread (2) ball links onto the pitch linkage. Thread them on equally. The final length of the link assembly will be 114mm from end – to – end, or 106mm from ball center –...

  • Page 43: Aileron Servo Installation

    AILERON SERVO INSTALLATION 31. Aileron Servo Installation Bag# Part# Description 5010 M3x8 SHCS 5110 M3 Washer Install the aileron servo assembly in between the collective arms. The angled edge of the servo mount faces to the front, and the servo bottom faces up. Use (2) M3x8 SHCS in the middle hole on each side of the servo mount.
  • Page 44 Put the ball on the Philips screw, followed by a M2 nut. Use threadlocker, but sparingly. Screw into the servo arm in one of the holes drilled so the ball will be facing up when installed on the servo. Put another M2 nut on the backside of the disc on the screw. Use threadlocker, sparingly. Repeat previous steps with the other screw and ball.

  • Page 45: Aileron Servo

    AILERON SERVO Servo Mount - mounting recessed screw side Mount Tab Mounting pushed into ear and grommet grommet 30. Aileron Servo Bag# Part# Description 1540 Aileron Servo Mount 1947 Plastic Servo Mount Tabs 5120 M2 Nut 52207 M2x10 Philips Screw 5137 M2x5 Ball The aileron servo mounts to the servo mount with the mounting ears of the servo sitting on...
  • Page 46 When attaching pushrods, we want to achieve a smooth, free movement with a minimum of freeplay. Due to the material that ball links are made of, you will find that some links are tighter than others. This happens as a result of the hot plastic being removed from the mold and shrinking in certain areas.

  • Page 47: Servo Arms And Linkages

    SERVO ARMS AND LINKAGES Now it is time to start connecting the various systems on the helicopter to the radio components. There are a few basic items to stay aware of when connecting push rods to servo arms. When mounting balls to the various servo arms and levers, or bell cranks, please use a thread-locking component to ensure that all of these critical items stay solidly attached.

  • Page 48: Collective Bellcrank Installation

    COLLECTIVE BELLCRANK INSTALLATION 29. Collective Bellcrank Installation Bag# Part# Description 5010 M3x8 SHCS 5105 M3 Washer On the left-hand side, press the single collective bellcrank onto the lower collective axle. The flat end of the axle fits into the elongated hole in the single bellcrank. Screw (1) M3x8 SHCS and (1) M3 washer into the end of the axle, capturing the single collective bellcrank onto the axle.

  • Page 49: Collective Arm Installation

    COLLECTIVE ARM INSTALLATION 28. Collective Arm Installation Bag# Part# Description 5010 M3x8 SHCS 5001 M3X4 SHCS 5110 M3 Washer Press (1) collective arm assembly onto each side of the upper collective axle. The flat ends of the collective axle fit into the elongated holes on the collective arms. The flanged bearings on the ends of the collective arms should slide over the elevator control shafts on the elevator yoke.

  • Page 50: Collective Arms

    COLLECTIVE ARMS 27. Collective Arms Bag# Part# Description 1616 Collective Arm 5195 Medium Balls 3031 5x8x2.5F Bearing Insert (1) 5x8x2.5F Bearing into each collective arm. Make sure that the bearing is seated and that the flange is flush. The flange is the outside of the arm. Insert (1) medium ball into the outside of each arm.
  • Page 51 Bag# Part# Description 1630 Collective Bellcrank Single 1625 Collective Bellcrank Triple 1610 Elevator Control Arm 5195 Medium Balls 5190 Short Balls 5200 Long Balls Insert (1) medium ball into the single collective bellcrank. Use threadlocker. Insert (2) short balls into the elevator control arm, both on the same side. Use threadlocker. Insert (1) medium ball into the triple collective bellcrank, on the arm that the elongated slot points to.

  • Page 52: Control Arms

    CONTROL ARMS 26. Control Arms Bag# Part# Description 1641 Aileron Bellcrank 1651 Elevator X Control Arm 3031 5x8x2.5F Bearing 5190 Short Balls 5195 Medium Balls 5030 M3x16 SHCS 5035 M3x20 SHCS 1645 Control Arm Jamnut Press (2) 5x8x2.5F bearings into the (2) aileron bellcranks and the elevator control xarm. The flanges should be seated flush.

  • Page 53: Gyro Tray And Battery Monitor

    GYRO TRAY AND BATTERY MONITOR 25. Gyro Tray and Battery Monitor Bag# Part# Description 1546 Gyro Mount Block 3 Hole 5090 M3x8 FHSCS 5010 M3x8 SHCS 1545 Gyro Mount 1550 Battery Monitor Mount Bolt (2) gyro mount blocks in between the sideframes above the lower collective axle. The single hole faces towards the rear.
  • Page 54 Lubricate the Bearing Carrier and the inside rear end of the Tailboom (the end with the holes) with silicone grease. Push the bearing carrier into the front of the tailboom with the bearing side of the bearing carrier facing forward. Push the bearing carrier into the tailboom about ½ way. Use a dowel about ½...

  • Page 55: Tailboom Assembly

    TAILBOOM ASSEMBLY 24. Tailboom Assembly Bag# Part# Description MISC 5105 M3 Locknut MISC 5110 M3 Washer 1535 Rudder Servo Mount MISC 109A Bearing Carrier 1667 Horizontal Fin Clamp Remove the (3) M3x40 SHCS. Attach the rudder servo mount using the (3) M3x40 SHCS just removed, with (6) M3 Washers and (3) M3 locknuts.
  • Page 56 23. Torque Tube Shortening Bag# Part# Description 5001 M3x4 SHCS 1665 Tailboom Clamp MISC 5050 M3x35 SHCS MISC 5055 M3x40 SHCS Temporarily attach the aluminum tail rotor gear box to the rear of the tailboom (the end with the holes) with (2) M3x SHCS. Temporarily attach the (3) tailboom clamps to the rear of the upper frame assembly with (3) M3x35 SHCS and (3) M3x40 SHCS.

  • Page 57: Torque Tube

    TORQUE TUBE 22. Torque Tube Bag# Part# Description 9015 Dogbone 9020 Dogbone Pin 5095 3x4 Set Screw (Dogbone) MISC 109D Collar MISC 5094 3x3 Set Screw (Collar) 1000 Aluminum Tail Rotor Gear Box 2117 Arrow Drive Shaft 1171 Tail Boom Push the Dogbone Pin to the hole in the ball end of the Dogbone.
  • Page 58 Drop the Engine Assembly approximately 1/2mm to allow clutch to “float” on the delrin clutch bushings. This is what allows the Bergen clutch to be self-aligning. Now tighten all engine mount screws. Apply threadlocker at this time.

  • Page 59: Upper Right Sideframe Installation

    UPPER RIGHT SIDEFRAME INSTALLATION 21. Upper Sideframe Installation Bag# Part# Description 5055 M3x40 SHCS 5175 29M Frame Spacer 5105 M3 Locknut 5015 M3x10 SHCS (for start shaft bearing block) 5110 M3 Washer MISC 5015 M3x10 SHCS (for tail transmission) MISC 5110 M3 Washer Test fit the right upper sideframe assembly by holding it up in position and putting in a few...

  • Page 60: Upper Frame Assembly

    COLLECTIVE AXLES Collective Axles 19. Collective Axles Bag# Part# Description 1620 Collective Axle Install (2) collective axles into the collective axle bearings on the inside of the left upper sideframe. UPPER FRAME ASSEMBLY 20. Upper Frame Assembly Bag# Part# Description 5010 M3x8 SHCS 1947...

  • Page 61: Main Shaft And Main Gear Installation

    MAIN SHAFT AND MAIN GEAR INSTALLATION 17. Main Shaft and Main Gear Installation Bag# Part# Description 5050 M3x35 SHCS Install main shaft assembly by attaching with (4) M3x35 SHCS. The screws goes through the holes in the sideframe and then through the holes in the main bearing assemblies. •...
  • Page 62 MAIN SHAFT ASSEMBLY Elevator Yoke Upgrade Option 16. Main Shaft Assembly Bag# Part# Description 1233 Main Shaft Assembly 1245 Split Main Shaft Collar Assembly 1250 Main Shaft Bearing Block Assembly Remove the shaft collar from the main shaft, and re-attach with threadlocker on the retaining screw.

  • Page 63: Clutch Installation

    CLUTCH INSTALLATION 15. Clutch Installation Bag# Part# Description 5015 M3x10 SHCS 5110 M3 Washers Set the clutch assembly onto the 2 delrin bushings on the fan. Attach the start shaft bearing assembly to the left upper sideframe with (2) M3x10 SHCS and (2) M3 Washers.

  • Page 64: Tail Transmission Assembly

    TAIL TRANSMISSION ASSEMBLY 14. Tail Transmission Assembly Bag# Part# Description MISC 1727 Tail transmission Bearing Block Aluminum MISC 3053 5x10x4 Flange Bearing MISC 1745 Pinion gear (Tail Transmission) MISC 1740 Pinion Spacer (Brass) MISC 5095 3x4 Set Screw (Pinion Gear) 1210 Coupler Pin 9010...

  • Page 65: Elevator Yoke Assembly

    ELEVATOR YOKE ASSEMBLY 13. Elevator Yoke Assembly Bag# Part# Description 1596 Elevator Control Yoke 5190 Short Ball 5110 M3 Washer 5001 M3x4 SHCS 1600 Elevator Control Shaft Long 1605 Elevator Control Shaft Short Press (1) elevator control shaft – short into the elevator control yoke. The flattened end of the control shaft fits into the special oblong shape hole in the center of the control yoke.

  • Page 66: Main Gear Assembly

    MAIN GEAR ASSEMBLY Long End Goes Into Gear 12. Main Gear Assembly Bag# Part# Description 1270 Main Gear 1265 Auto Hub Assembly 5308 M3x8 Special Low Head Cap Screw Break the sharp edge of bore in main gear before installing on auto hub. Position the auto hub assembly so that the longer end is facing the main gear.

  • Page 67: Left Upper Frame Assembly

    LEFT UPPER FRAME ASSEMBLY 11. Left Upper Frame Assembly Bag# Part# Description 5175 29M Frame Spacer 5055 M3x40 SHCS 5010 M3x8 SHCS 5170 26M Frame Spacer Attach (5) 29M Frame Spacers to the left lower frame with (5) M3x40 SHCS. The Spacers are not threaded, so they will just sit on the screws Place the upper left sideframe on the (5) protruding screws and thread on (5) 26M Frame Spacers.

  • Page 68: Mount Collective Bearings

    MOUNT COLLECTIVE BEARINGS Inside sideframe. Flange Is inside Outside Sideframe. No flange 10. Mount Collective Bearings Bag# Part# Description 1475 Upper Frame 1635 Collective Shaft Bearing Cup 3035 6x10x3 Bearing Place 2 Collective Shaft Bearing Cups into one side of one of the upper sideframes. Install the flange of the bearing cups on the same side of the frames.

  • Page 69: Mount Lower Servos

    MOUNT LOWER SERVOS Throttle Servo Elevator Servo 9. Mount Lower Servos Bag# Part# Description 1947 Plastic Servo Mount Tabs Prepare the servo with the hardware provided with the radio system: install the rubber grommets on the servo mounting ears, and then install the servo mount tabs into the grommets down from the top of the servo ear.

  • Page 70: Throttle Arm

    THROTTLE ARM Half Full Idle Short Ball Set Screw Throttle Arm 8. Throttle Arm Bag# Part# Description 2045 Throttle Arm - Gas 5190 Short Ball Screw the Short Ball into the throttle arm. Do not overtighten the ball into the plastic. Mount the throttle arm onto the carburetor.
  • Page 71 3x10M SHCS 3M Flat Washer 4x16M SHCS Motor Mount 2 Places 4M Flat Washer Bracket Attach the Motor Mount Bracket to the head of the engine with (1) 4x16M SHCS and (1) 4M flat washer. Do not use threadlocker at this time. This will be adjusted later. Attach the ends of the motor mount bracket to the lower side frames using (2) 3x10M SHCS and (2) 3M flat washers.
  • Page 72 ENGINE MOUNTING 3x8M SHCS Motor Mount 4 Places Spacer 2 Places 4x16M SHCS 4M Flat Washer 2 Places 7. Engine Mounting Bag# Part# Description 2040 Motor Mount Spacer - Gas 5010 3x8M SHCS 5065 4x16M SHCS 5015 3x10M SHCS 5110 3M Flat Washer 5109 4M Flat Washer...

  • Page 73: Clutch Bushing Installation

    CLUTCH BUSHING INSTALLATION 4x16M SHCS Delrin Bushing Steel Insert Countersink Clutch Assembly 6. Clutch Bushing Installation Bag# Part# Description 1300 Steel Insert 1295 Delrin Bushing 5065 4x16M SHCS 1275 Clutch Assembly Carefully examine the (2) steel inserts. There is one end that has a noticeable countersink on the inside edge.

  • Page 74: Starter Mounting

    STARTER MOUNTING Pull Start Adapter 5x12M FHSCS 3 Places Pull Start Adapter 4x12M SHCS 4 Places For Left-Hand Starting For Right-Hand Starting 5. Starter Mounting Bag# Part# Description 5091 5x12M FHSCS 5060 4x12M SHCS 2036 Pull Start Adapter Pull Starter (provided with engine) Mount the Pull Start Adapter to the back of the engine with (4) 5x12M FHSCS.
  • Page 75 Remove the fan hub wrench. Trial fit the fan shroud onto the fan shroud mount. The fan shroud should fit against the mount flat without any gaps. Lightly sand with a sanding block if necessary to make sure the shroud does sit flat. Attach the fan shroud to the mount with (4) 3X16 SHCS and 3M locknuts.

  • Page 76: Fan And Shroud Assembly

    Place the fan assembly on the crankshaft. Bolt the fan hub wrench (See your dealer or Bergen R/C Helicopter) to the fan hub with (2) 4x16 SHCS from Bag 6. This is temporary only. Do not use threadlocker.

  • Page 77: Landing Gear Assembly And Mounting

    LANDING GEAR ASSEMBLY AND MOUNTING M3x4 Set Screws (4 plcs) 3. Landing Gear Assembly and Mounting Bag# Part# Description 1574 Landing Gear Set (Black or White) 5095 M3x4 Set Screws 5030 M3x16 SHCS 5105 M3 Lock Nuts Slide a plastic skid strut over one of the metal skids. You may find it necessary to heat the plastic strut in hot water or with a hot air gun in order to expand it, which will enable it to slide over the metal tube.

  • Page 78: Battery Tray

    BATTERY TRAY M3x8 FHCS 6 Places Bottom View Battery Tray, Countersink Holes Up Battery Tray, Spacers Installed. Top View M3x13 Set Screw and Short Standoff 2 Places M3x8 SHCS 2 Places Battery Tray Installed, Top View 2. Battery Tray Bag# Part# Description 1520...

  • Page 79: Lower Frames

    LOWER FRAMES 1. Lower Frames Bag# Part# Description 1506 Lower Frame (Left) 1507 Lower Frame (Right) 1560 Skid Bar - Gas 5090 M3x8 FHCS On a flat surface, assemble lower frame (left and right) to the (2) skid bars. The countersink holes go to the outside and the frames go on the outside of the vertical portions of the skid bars.
  • Page 80 1983 PUSHROD ENDS 1956 BALL LINK 2.5 5105 3M LOCKNUT 5030 3X16M SHCS 1709 TAILBOOM SUPPORT SET 1710 TAIL BOOM SUPPORT STRUTS 1715 TAILBOOM SUPPORT STRUT ENDS BAG 11 1956 BALL LINKS 2.5 1947 PLASTIC SERVO MOUNT TABS 1948 WIRE CLIP 1985 ELEVATOR LINKAGE 130M 1990...
  • Page 81 3071 10X15X4 FLANGE BEARING 3055 5X13X4 BEARING 1000E 10M PIN 1210 12M PIN 1766 BEVEL GEAR SET BEVEL GEAR SHORT SHANK BEVEL GEAR LONG SHANK 1000I INPUT SHAFT FOR GEAR BOX 1000D OUTPUT SHAFT FOR BLADE GRIPS 1000J BRASS SPACER TUBE 5025 3X5 PAN HEAD SCREW 5001...
  • Page 82 1215 SWASH PLATE ASSEMBLY 5195 MEDIUM BALL 5210 SWASH PLATE ANTI ROTATION ASSEMBLY BAG 10A ASSEMBLY 1 TAIL ROTOR BLADE GRIPS #231 1815 TAIL ROTOR MAIN HUB 5M 230A BLADE GRIP 3054 5X10X4 BEARING 3052 5X10X4 THRUST BEARING 5110 3M FLAT WASHER 5015 3X10 SHCS 5146...
  • Page 83 1651 ELEVATOR X CONTROL ARM 3031 5X8X2.5F BEARING 5035 3X20M SHCS 1610 ELEVATOR CONTROL ARM 1230 ANTI ROTATION BRACKET 5105 3M LOCK NUT 1545 GYRO MOUNT 1550 BATTERY MONITOR MOUNT 1546 GYRO MOUNT BLOCK 3 HOLE 5090 3X8M FHSCS BAG 8 1155 SEESAW TUBE 1160...
  • Page 84 2030 MUFFLER SPACER – GAS 5109 4M FLAT WASHER 2036 PULL START ADAPTOR 5190 SHORT BALL 1980 140M THROTTLE LINKAGE 5141 3X18M SHCS 5105 3M LOCKNUTS 231B SPECIAL WASHERS BAG 5 1475 UPPER FRAME 1635 COLLECTIVE SHAFT BEARING CUP 3035 6X10X3 BEARING 1620 COLLECTIVE AXLE...

  • Page 85: Parts List

    PARTS LIST INTREPID GAS TORQUE TUBE DRIVE BAG 1 1506 LOWER FRAME (RIGHT) 1507 LOWER FRAME (LEFT) 5175 29M FRAME SPACERS 5055 3X40M SHCS 1560 SKID BAR – GAS 5090 3X8M FHCS 1520 BATTERY TRAY - GAS 1530 BATTERY TRAY SPACER – GAS...
  • Page 86 Bergen Distributorship. If you do not understand any aspect of this warranty, you may contact Bergen Machine & Tool for clarification. IF YOU DO NOT AGREE WITH ANY ASPECT OF THIS WARRANTY, RETURN THE UNASSEMBLED HELICOPTER TO YOUR MANUFACTURER FOR A REFUND.
  • Page 87 Bergen R/C Helicopters believes that information contained within its published materials is accurate as of the date of publication, and is not responsible for inadvertent errors or omissions. Bergen R/C reserves the right to make changes and improvements in its products without notice.
  • Page 88 Consumer Warranty IMPORTANT! Before building the INTREPID GAS Helicopter kit, read and fully understand the following warranty, and review the entire Construction Manual. By building and/or flying this helicopter you indicate your acceptance of the following warranty terms and conditions, and further agree to build and operate this helicopter in safe and responsible manner.
  • Page 89 Introduction The first of its kind, interchangeable modular engineered helicopter to accommodate the beginner to a FAI expert… An idea in 1994 to manufacture an interchangeable, modular helicopter, led to the research and development in 1995. Focusing on quality, engineering details, and price, a prototype was produced. After extensive test...
  • Page 90 Construction Manual Acknowledgments Bergen R/C Helicopters wishes to thank the facilities and friends for their continuing support during the development of the Intrepid Helicopter. The Instruction Manual and illustrations were completed by Dan Williams along with the input of numerous customers and staff.
  • Page 91 IT IS YOUR EXCLUSIVE RESPONSIBILITY TO PROPERLY BUILD, MAINTAIN AND OPERATE THIS HELICOPTER. Bergen R/C Helicopters has spent considerable time making this product reliable and easy to build, but only the operator can insure that it is safe.

  • Page 92: Table Of Contents

    TAIL PITCH ASSEMBLY ........................79 PITCH BELLCRANK.......................... 81 TAIL BLADES ............................ 82 RUDDER SERVO..........................83 TAILBOOM SUPPORT STRUTS....................... 85 RUDDER PUSHROD .......................... 86 FINS ..............................88 FUEL TANK ............................89 CANOPY.............................. 91 FINAL ADJUSTMENTS ........................93 ENGINE BREAK-IN ........................... 94...
  • Page 93 INTREPID GAS Table Of Contents PARTS LIST ............................11 LOWER FRAMES..........................17 BATTERY TRAY..........................18 LANDING GEAR ASSEMBLY AND MOUNTING................19 FAN AND SHROUD ASSEMBLY..................... 20 STARTER MOUNTING........................22 CLUTCH BUSHING INSTALLATION ..................... 23 ENGINE MOUNTING ........................24 THROTTLE ARM ..........................26 MOUNT LOWER SERVOS ........................

  • Page 95: Intrepid Gas

    INTREPID GAS Owners Manual Assembly Instructions Rev. 1...

Table of Contents