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AVANT Aurora Ultimate 90 Assembly Manual

Model helicopter avant aurora ultimate 90
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Summary of Contents for AVANT Aurora Ultimate 90

  • Page 2: Liability Disclaimer

    Aurora AVANT Ultimate 90 Assembly Manual urora AVANT Ultimate 90 Assembly Manual V2.00 LIABILITY DISCLAIMER This kit is for a radio controlled (RC) helicopter. RC Helicopters are not toys. Moving parts can present a hazard to operators, bystanders and anyone or anything that could be reached by the RC helicopter. Improper...
  • Page 3 Aurora AVANT Ultimate 90 Assembly Manual   Before you start assembling: Get the latest manual: It’s highly recommended that you get the latest version of the manual. Please download a copy by clicking here and use that copy instead of this one.
  • Page 4 Aurora AVANT Ultimate 90 Assembly Manual M3x8 (2) AV00-100-421 AV00-100-604 AV00-100-604 AV00-200-504 Install five 26mm spacers M3x8 (1) AV00-100-421 AV00-100-604 M3x8 (3) AV00-100-421 Not used M3x8 (2) AV00-200-744 stubs and two 5mm long grommets Not used AV00-100-683 M3x8 (2) AV00-100-421 Cut the rubber strip into ten 10mm long.
  • Page 5 Aurora AVANT Ultimate 90 Assembly Manual AV00-100-609 Using two M3x8 screws install the Gyro mount plate. Do not use blue Loctite yet because they will be loosened later during the installation of the boom clamp. M3x8 (2) AV00-100-421 Bag #2: Main Gear assembly, Main shaft installation and Left side frame stiffener M2.5x8 (6) AV00-100-410...

  • Page 6: Very Important Note

    Aurora AVANT Ultimate 90 Assembly Manual AV00-200-671 AV00-200-676 (Sharp edge should point toward the sleeve) Install the constant drive gear onto the constant drive gear hub. Slide the main sleeve into the one-way sprag clutch with the key coinciding with the key slots and then slide the constant gear hub into the protruding main sleeve bottom.
  • Page 7 Aurora AVANT Ultimate 90 Assembly Manual For the next step hold pressure on the main shaft's middle and bottom bearing blocks against each other while tightening the bearing block's bolts shown on the next illustration. No play should be allowed in between the blocks and the main sleeve.
  • Page 8 Aurora AVANT Ultimate 90 Assembly Manual Bag #3: Clutch Stack, Clutch Bell assembly.  Install the gear ratio plate making sure that the notch points toward the back of the helicopter. AV00-200-506 Ratio plate M3x6 (2) AV00-100-420 Glue the Clutch liner to the Clutch Bell using 30-minute epoxy making sure to trim the length of the liner strip to match the bell precisely.
  • Page 9 Aurora AVANT Ultimate 90 Assembly Manual Bag #4: Tail Pickup gear mechanism and gear meshing method. AV00-200-619 Assemble the vertical pickup shaft as shown on the left. The roll pin (black one) is the one above and the dowel pin (silver one) is the one at the bottom side.

  • Page 10: Very Important

    Aurora AVANT Ultimate 90 Assembly Manual  VERY IMPORTANT!!! READ AND FOLLOW THE TAIL GEAR MESH METHOD Failure to do so can cause the tail gears to fail in flight This is the method used to do a correct mesh on the Aurora tail gears. This applies to both the front set (the set inside the frames) and the back set (the set inside the tailcase).
  • Page 11 Aurora AVANT Ultimate 90 Assembly Manual Wrong alignment case #1: Top gear too forward Wrong alignment case #2: Bottom gear too forward Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite...
  • Page 12 Aurora AVANT Ultimate 90 Assembly Manual Correct tooth face alignment: Flush alignment is easily achieved because the kit brings four sets of three bearings spacing washers of 0.1, 0.2 and 0.3mm thickness. Combining them you can get from 0.1mm to 0.6mm spacing (0.1), (0.2), (0.1+0.2), (0.3), (0.3+0.1),...
  • Page 13 Aurora AVANT Ultimate 90 Assembly Manual 2) No Play: The second and very important thing to make sure you have is that there is absolutely no play between the gears. In order to make sure that there is no play between the gears hold one of the shaft firmly while trying to rotate the other one back and forth.
  • Page 14 Aurora AVANT Ultimate 90 Assembly Manual M3 Locknut (2) M3x8 (1) AV00-100-421 AV00-100-320 Bag #6: Right Frame, frame bellcrank and Tail AV00-200-506 AV00-200-511 boom clamp. AV00-200-505 Install the sacrificial tabs and canopy mount posts as M3x8 (2) previously done in the left...
  • Page 15 Aurora AVANT Ultimate 90 Assembly Manual M3x35 (4) AV00-100-428 Install the boom clamps with the through bolts as shown. Do not tighten them until the boom is installed. M3 locknut (4) AV00-100-320 AV00-200-753 M3 washer (4) AV00-100-302 Assemble the tail frame bellcrank as shown.
  • Page 16 Aurora AVANT Ultimate 90 Assembly Manual M4x4 (1) Cup point Setscrew AV00-100-357 AV00-100-618 AV00-200-667 AV00-100-619 M4x4 (1) Cup point Setscrew AV00-100-357 AV00-100-620 AV00-100-622 (Long) AV00-200-620 Install the seven balls and the guide pin on AV00-100-624 the pre-assembled swashplate as shown.
  • Page 17 Aurora AVANT Ultimate 90 Assembly Manual Install AV00-200-621 Main Shaft Collar using two M4x4 (2) Flat AV00-100-351 AV00-200-733 M3x8 (4) AV00-100-421 Slide the Swashplate onto the main shaft and install the CCPM guide with the four screws as shown. Bag #8: Fan hub, Fan, Clutch and motor mount sides...
  • Page 18 Aurora AVANT Ultimate 90 Assembly Manual M4x8 (2) AV00-100-430 AV00-200-290 One-way Bearing AV00-200-603  Add a few drops of oil to the rollers to lubricate the one-way bearing. Make sure you don’t get any in the clutch shoes that could make the clutch slip.
  • Page 19 Aurora AVANT Ultimate 90 Assembly Manual Bag #9: Fan shroud installation  Now that the engine is in place rotate the starter shaft and make sure it’s aligned with the one-way bearing. Tighten the eight bearing block screws accordingly. And the engine and motor mount sides bolts.
  • Page 20 Aurora AVANT Ultimate 90 Assembly Manual Bag #10: Landing gear installation AV00-200-670 Insert the landing gear skids into the landing gear struts as shown. Use the frames as a M3x5 (4) AV00-100-358 reference to space them approximately where they go.
  • Page 21 Aurora AVANT Ultimate 90 Assembly Manual Adjust the separation of the landing gear struts to make them match the holes on the frames. Using the provided hardware install the front landing gear strut on the M3x10 (4) AV00-100-422 frames as shown.
  • Page 22 Aurora AVANT Ultimate 90 Assembly Manual Bag #11: Bottom plate and right side stiffener. Install the bottom plate with the four screws as shown. Once the M3 locknut (2) AV00-100-320 back screws are installed install the front side with the hardware M3 washer (2) AV00-100-302 provided.
  • Page 23 Aurora AVANT Ultimate 90 Assembly Manual Bag #12: Fuel Tank hardware preparation Install the previously assembled fuel tank by pushing the top and bottom effectively squeezing the tank to make it fit in between the frame’s rubber edges.  Remember than in...
  • Page 24 Aurora AVANT Ultimate 90 Assembly Manual Installing the Torque Tube Bearings: Put a couple of drops of thin CA on the TT in the area where you're going to install the bearing and while keeping it horizontal rotate the TT making the bead cover the area around where the bearing fits.
  • Page 25 Aurora AVANT Ultimate 90 Assembly Manual Bag #14: Tail assembly.  When tightening the 6mm shaft collar pull the shaft slightly outward while pushing the collar inward to eliminate any play. AV00-100- 332 AV00-100- 330 AV00-200- 600 AV00-200- 608 AV00-200- 610...
  • Page 26 Aurora AVANT Ultimate 90 Assembly Manual  When installing the tail yoke into the brass sleeve start by pushing it into the sleeve. Once the smaller ID area is reached then continue by screwing it in. If you start by screwing it in you might prevent it from aligning correctly with the sleeve.
  • Page 27 Aurora AVANT Ultimate 90 Assembly Manual Tail L Bellcrank. AV00-200- 260 AV00-200- 302 AV00-200- 667 AV00-200- 725 AV00-200- 260 Fin and Tail Clamp Assembly. M3x10 (1) Button Head AV00-100- 443 M3x12 (2) AV00-100- 423 M3x12 (1) AV00-100- 423 AV00-200- 724...
  • Page 28 Aurora AVANT Ultimate 90 Assembly Manual Bag # 15: Boom Supports and Horizontal Fin.  Clean the inside thoroughly with alcohol or acetone and use epoxy of at least 30-minute duration and let it cure before use. Make sure both ends are...
  • Page 29 Aurora AVANT Ultimate 90 Assembly Manual Bag #16: Head assembly Head Step 1) Install the flybar carrier inside the AV00-200-660 yoke with the spacers and 12mm M3 screws, read below first. IMPORTANT Note:  Prepare both M3 bolts by cleaning them with rubbing alcohol.
  • Page 30 Aurora AVANT Ultimate 90 Assembly Manual   When Inserting into Yoke Check for burrs inside head Head Step 3) use soapy water as lubricant. button bolt holes. Deburr as needed. AV00-200-717 Rigid Dampener w/O- Rings AV00-200-686 Smooth Spindle AV00-200-717...
  • Page 31 Aurora AVANT Ultimate 90 Assembly Manual   Smaller Inside Larger Inside diameter hole diameter hole Head Step 4) AV00-200-470 M5x14mm (2) AV00-100-439 AV00-200-665 AV00-100-304 AV00-200-200 AV00-200-652 AV00-200-304 Important note: Grease both thrust bearing races and center before installation. Install the provided 16x1x10 bearing “spacer” first.
  • Page 32 Aurora AVANT Ultimate 90 Assembly Manual Mixing Arm head speed settings. Default Delta Holes Default Delta Holes M3 x 6mm (4) Use four M3 x 6mm bolts. Use red Loctite here on all four bolt threads. The indicated Delta holes are set to make the faster head setting track better.
  • Page 33 Aurora AVANT Ultimate 90 Assembly Manual Delta is set by the position of the mixing arm center screw. Closer to the blade grip is snappier and opposite to it tracks better. Below is a more extensive explanation of delta, mixing arm and flybar arm settings for those interested. The default delta position used is...
  • Page 34 Aurora AVANT Ultimate 90 Assembly Manual AV00-200-668 AV00-100-604 AV00-200-655 M3x16mm button head screw AV00-100-445 Install the AV00-200-651 555mm flybar and secure with two M4 flat point setscrews. Use blue Loctite here. Assemble the washout arm as shown here. Clean any excess plastic flash with an X-Acto knife and make sure the Y-Link rotates easily around the pin.
  • Page 35 Aurora AVANT Ultimate 90 Assembly Manual Use the 1mm spacer to install the washout arms. Use blue Loctite here. Do not tighten the washout arm screws too much otherwise the washout base will bind against the shaft. It’s designed that way so you can tighten it as the washout base wears out with use.
  • Page 36 Aurora AVANT Ultimate 90 Assembly Manual Head Step 5) For the rod coming from the swashplate (left) using holes closer to the center make the head more active and away from center make the head more stable. For the rod from the flybar (right) using holes closer to the center make the head less active or more stable and away from center more active or less stable.
  • Page 37 Aurora AVANT Ultimate 90 Assembly Manual Holes on the bladegrip and pitch arm affect the delta. Lower delta numbers are more active. Higher delta numbers are more stable. For all the delta settings please see diagram for delta settings in the manual.
  • Page 38 Aurora AVANT Ultimate 90 Assembly Manual Important note: When using Active and Super Active settings the forces applied to the CCPM servos are larger than normal so plastic servo gears can suffer or break. Metal geared high torque servos are strongly recommended for those settings.
  • Page 39 Aurora AVANT Ultimate 90 Assembly Manual You can use up to 18 different delta settings in this head. Setting pictured in the assembly pictures above corresponds to setting number 7, which is a good point for 3D. Lower delta position numbers = more stability (3D). Higher Delta position numbers = more response.
  • Page 40 Aurora AVANT Ultimate 90 Assembly Manual If you want you can also adjust the phasing to match your blades lead-lag angle and eliminate any tail corkscrewing during rolls if your blades have some. If you need to correct you can start with about 1 degree and build up from there.
  • Page 41 Aurora AVANT Ultimate 90 Assembly Manual AV00-200-301 Use two swashplate balls per mixing arm. Use red Loctite here. Left ball closer to the center makes it faster (more swashplate to blades input). Right ball closer to the right makes it also faster (less flybar stabilization).
  • Page 42 Aurora AVANT Ultimate 90 Assembly Manual Head Step 7) AV00-200-668 AV00-100-604 AV00-200-655 M3x16mm button head screw AV00-100-445 Use an M3 ball blue Loctite here. Head Step 8) M4x4 flat point setscrew AV00-100-351 Install the AV00-200-651 555mm flybar and secure with two M4 flat point setscrews. Use blue Loctite here.
  • Page 43 Aurora AVANT Ultimate 90 Assembly Manual Head Step 9) M4x4 flat point setscrew AV00-100-351 AV00-200-653 AV00-200-710 Use two M4 flat point setscrews Head Step 10) M4x10 AV00-100-431 Install two M4 screws onto the Main shaft. Red Loctite here and make them very tight.
  • Page 44 Aurora AVANT Ultimate 90 Assembly Manual Head Step 11) AV00-100-334 AV00-200-260 AV00-200-667 AV00-200-752 AV00-200-751 Assemble the washout arm as shown here. Clean any flash with an X-Acto knife and make sure the Y-Link rotates easily around the pin. AV00-200-301 M3x20mm button head screw AV00-100-447 Use the 1mm spacer to install the washout arms.
  • Page 45 Aurora AVANT Ultimate 90 Assembly Manual Head Step 12) AV00-200-728 Long Ball Link (4) AV00-200-995 85mm threaded rod 71 mm distance between the two ball link ends. Install the supplied 85mm threaded rod and leave AV00-200-990 16mm threaded rod 3.5 mm distance between the ball link ends.
  • Page 46 Aurora AVANT Ultimate 90 Assembly Manual Head Step 13) AV00-200-728 Long Ball Link (4) 22.5 mm distance between the ball link ends. Install the 35mm flybar control arm threaded rod and links Head Step 14) M3x16 Stainless Steel Screw AV00-100-452 (2) AV00-200-659 Install the head button with the Stainless steel screws.
  • Page 47 Aurora AVANT Ultimate 90 Assembly Manual Bag #17: Radio installation For the cases where the servo goes inside the frames here’s the method to get it into the frames. Remember to take the rubber grommets of when installing larger servos like the...
  • Page 48 Aurora AVANT Ultimate 90 Assembly Manual AV00-200- 741 Thick Ball link AV00-200- 993 AV00-200- 681 AV00-200- 554 Thread the thick ball link into the 50mm threaded rod and use it to glue the threaded rod into the carbon rod with 30-minute. Epoxy or JB Weld. Once cured unthread it and then slide into the brass sleeve using pliers holding the ball link by the flat areas.
  • Page 49 Aurora AVANT Ultimate 90 Assembly Manual Front Tail Control Rod assembly. Repeat process and part numbers from above. AV00-200- 758 Tail Pushrod Guide set Install the long pushrod guide toward the front and the short toward the back. If needed after alignment is done use a drop of CA to fix the pushrod guide in place.
  • Page 50 Aurora AVANT Ultimate 90 Assembly Manual AV00-200- 995 (2) 85mm threaded rod AV00-200- 991 (3) 35mm threaded rod AV00-200- 997 (2) 135mm threaded rod AV00-200- 994 (4) 80mm threaded rod AV00-200- 553 Short Carbon pushrod AV00-200- 996 (1) 100mm threaded rod...
  • Page 51 Aurora AVANT Ultimate 90 Assembly Manual Recommended threaded rod distances. All distances indicated below refer to distances from end to end of ball links. Different servo brands will cause distances to differ from the ones listed below. 3.5mm x 2 71mm x 2 22.5mm x 2...
  • Page 52 Aurora AVANT Ultimate 90 Assembly Manual IMPORTANT Note:  All the servo arms used on the cyclic servos should have a center-to-hole distance of 12.5mm to 13mm. 65.75mm x 2 69.5mm x 2 Cut wheel off as shown to prevent binding with the ball link 83.5mm x 1...
  • Page 53 Aurora AVANT Ultimate 90 Assembly Manual Ball links fit and sizing. If needed for a final fit you can squeeze the ball link ring slightly with some pliers to make it a bit loser. Keep in mind that the important thing is to make sure your ball links are secure so check and make sure the balls don’t come...