Rev 1.
INTRODUCTION Rev 1.0M 01 | INTRODUCTION 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR 04 | BELT TENSION ARM 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 hobby.
LEFT FRAME 107-110 Pivot Ball 2.5mm x 4.5mm 101-306 M3x6 Button Head Rev 1.0M 100-274 M2.5 Washer 305-112 Elevator Tail Servo Mount 01 | INTRODUCTION 02 | FRAME 100-266 M2.5x6 Socket Head 516-219 Spring Post 105-117 Key Chain Canopy Mount, Female 17mm 516-215 Battery Tray Rail IMPORTANT: Install battery tray rail as indicated with the rail slot positioned near the bottom. Use CA to secure bolts and do not overtighten.
RIGHT FRAME 105-117 Key Chain Canopy Mount, Female 17mm Rev 1.0M 101-306 M3x6 Button Head 01 | INTRODUCTION 02 | FRAME 516-202 Main Frame Right 02 | FRAME 03 | LANDING GEAR IMPORTANT: Left and right frames are not similar. Take care to use correct frame and orientation at this step. The left frame (previous page) contains the cut out for the tail servo and mount hole for the spring post. IMPORTANT: Install battery tray rail as indicated with the rail slot positioned near the bottom.
MAIN SHAFT BLOCKS 100-204 M2x4 Socket Head (2) Rev 1.0M 108-104 10x15x4 Radial Bearing 01 | INTRODUCTION 02 | FRAME 02 | FRAME 516-203 Main Shaft Bearing Block - Top 100-273 M2 Washer (2) ! IMPORTANT: Apply BLUE threadlocker where indicated and do not overtighten. To ensure proper fit, wear, and a predictable lifespan, main shaft bearings are secured via threadlocker and pre-assembled. Heat will be required for replacement. Apply GREEN or RED threadlocker when replacing.
BOOM BLOCKS AND GYRO TRAY Rev 1.0M 01 | INTRODUCTION 02 | FRAME 103-256 M2.5x6 Flat Head Cross Recess (4) 516-213 Radio Plate 103-256 M2.5x6 Flat Head Cross Recess (4) Apply BLUE threadlocker where indicated and do not over-tighten the cross-head screws.
FRAME BOLTS Rev 1.0M Right x17 100-266 M2.5x6 Socket Head Left x18 100-266 M2.5x6 Socket Head Apply BLUE threadlocker to all frame bolts. Do not fully tighten bolts at this step.
FRAME ALIGNMENT Place airframe on a true flat surface to verify that frames are square before tightening all frame bolts. Temporarily insert the main shaft to verify frame alignment. Rev 1.
ESC PLATE Rev 1.0M Apply BLUE threadlocker where indicated and do not over-tighten the cross-head screws. 103-256 M2.5x6 Flat Head Cross Recess (4) 01 | INTRODUCTION 02 | FRAME 02 | FRAME 516-214 ESC Plate 03 | LANDING GEAR 04 | BELT TENSION ARM 05 | MAIN DRIVE 516-200 Frame Mount Spacer (2) 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY 08 | SETTING BELT TENSION 09 | SWASH PLATE 10 | CYCLIC SERVOS 11 | ANTI-ROTATION GUIDE 12 | TAIL SERVO 100-266 M2.
LANDING GEAR MOUNTS Apply BLUE threadlocker where indicated. Rev 1.0M 01 | INTRODUCTION 100-266 M2.
LANDING GEAR Apply BLUE threadlocker where indicated. 100-464 M4x4 Set Screw (4) Rev 1.0M TIP: Use CA or 30-minute epoxy to secure skid tube plugs.
BELT TENSION ARM IMPORTANT: Remove bolts, pivot ball, and apply BLUE threadlocker where indicated. Rev 1.0M 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR 101-325 M3x25 Button Head Bolt IMPORTANT: Guide Pulley 516-405 with wall guides is the stationary pulley. 101-316 M3x16 Button Head Bolt 106-301 0.
BELT TENSION ARM Apply BLUE threadlocker where indicated. Rev 1.0M 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR | BELT TENSION 04 | BELT04 TENSION ARM ARM 05 | MAIN DRIVE 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY 100-266 M2.5x6 Socket Head (2) 08 | SETTING BELT TENSION 09 | SWASH PLATE 516-413 Tail Belt 10 | CYCLIC SERVOS 11 | ANTI-ROTATION GUIDE 12 | TAIL SERVO 13 | MAIN HEAD Insert tail belt at this stage of the build.
MAIN GEAR AND AUTO HUB Rev 1.0M ! 516-302 14x23x2mm Bronze Bushing 108-111 One-way Bearing PRE-INSTALLED BEARING (DISASSEMBLY NOT REQUIRED) 01 | INTRODUCTION 02 | FRAME 200-506 516 Auto Hub Assembly IMPORTANT: Apply a thin coating of RED threadlocker to the outside of the bronze bushings. Use only a thin layer to prevent contamination of the oneway bearing inside the hub. IMPORTANT: Remove and apply BLUE threadlocker and do not overtighten 101-308 M3x8 Button Heads in the main gear.
MAIN BELT DRIVE PULLEY Rev 1.0M 01 | INTRODUCTION IMPORTANT: Full disassembly is required. Apply BLUE threadlocker to ALL bolts. Do not over-tighten bolts.
MAIN DRIVE ASSEMBLY TIP: Use extreme pressure synthetic grease to lubricate Delrin washers. Avoid applying grease to the sleeve and one-way bearing. Boto-Lube Part BD-001 for optimal performance. Rev 1.0M 01 | INTRODUCTION 516-301 Auto Hub Sleeve OIL SLEEVE 02 | FRAME TIP: Lubricate the Auto Hub Sleeve and one-way bearing with Tri-Flow or equivalent light machine oil. Do not use grease.
MAIN DRIVE INSTALLATION Feed tail belt around the main drive pulley at this stage of the build. 8.0mm Rev 1.0M MAIN SHAFT ORIENTATION: The hole nearest the end of the shaft is the top. 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR 516-104 Main Shaft 04 | BELT TENSION ARM 516-413 Tail Belt Position indicated shim below main drive unit and then insert the M3x25 Shouldered Bolt. IMPORTANT: Do not overtighten! 109-111 10x12x0.25mm Main Shaft Shim 05 | MAIN DRIVE 05 | MAIN DRIVE TIP: Use a 5.
BOOM INSTALLATION Boom Installation Feed tail belt through the boom and insert boom into the boom support blocks until positioned as indicated. Rev 1.
TAIL - TAIL PITCH LEVER IMPORTANT: Remove and secure pivot ball using RED threadlocker. TIP: CA may be used to secure Bell Crank Insert Guide. Rev 1.
TAIL - RIGHT SIDE Apply RED or BLUE threadlocker where indicated. Rev 1.
TAIL - SHAFT AND PULLEY IMPORTANT: Apply RED threadlocker to set screw and verify it fully engages flat spot on the tail output shaft. Heat may be required when removing. Rev 1.
TAIL - BELT AND LEFT SIDE Verify tail belt is not twisted then rotate 90 degrees COUNTER-CLOCKWISE and install onto tail shaft pulley. Rev 1.0M 90o 01 | INTRODUCTION Apply BLUE threadlocker where indicated. 02 | FRAME 03 | LANDING GEAR 101-308 M3x8 Button Head 04 | BELT TENSION ARM 516-409 Vert Tail Fin 05 | MAIN DRIVE 06 | BOOM INSTALLATION 101-306 M3x6 Button Head IMPORTANT: Tail belt should only have ONE 90 degree twist.
TAIL - BELT GUIDE PULLEY IMPORTANT: Do not overtighten M3x40 bolt 100-340. Rev 1.0M 01 | INTRODUCTION 109-311 3x5x11.6 Spacer 108-383 3x8x3 Radial Bearing 109-353 3x5x2.8 Brass Spacer 02 | FRAME 03 | LANDING GEAR 516-405 Tail Guide Pulley 108-383 3x8x3 Radial Bearing 04 | BELT TENSION ARM 109-311 3x5x11.
TAIL - PITCH SLIDER IMPORTANT: Disassemble and apply a small amount of RED threadlocker to the brass sleeve and tighten gently. DO NOT OVERTIGHTEN or damage can occur. 320-320 Tail Pitch Slider Threaded Rev 1.0M 108-812 8x12x2.5 Radial Bearing 320-319 Tail Bearing Ring Aluminum 01 | INTRODUCTION 02 | FRAME 108-812 8x12x2.5 Radial Bearing 606-921 Tail Pitch Link Pin (2) 03 | LANDING GEAR ! 506-920 E-Ring (2) 04 | BELT TENSION ARM 05 | MAIN DRIVE IMPORTANT: Brass sleeve is REVERSE THREADED.
TAIL - HUB AND GRIPS Rev 1.0M ! 107-106 Pivot Ball NOT 107-110 TIP: Use extreme pressure synthetic grease on all thrust bearings for optimal performance. Boto-Lube Part BD-001 IMPORTANT: Full disassembly is required. Apply RED threadlocker to both tail grip pivot balls and bolts.
TAIL - FINAL ASSEMBLY IMPORTANT: Secure tail hub set screw using RED threadlocker. Rev 1.0M For optimal performance, apply light machine oil to the tail shaft.
BELT TENSION SETTING IMPORTANT: Adjust belt tension by sliding tail box until tension arm is positioned 90 degrees to the frame, then secure with indicated bolt. Rev 1.0M NOTE: Verify tailbox alignment, vertical fin should be parallel to the frames.
SWASH PLATE Rev 1.0M 100-214 M2x14 Socket Head (4) 107-110 Pivot Ball 2.5mm x 4.5mm (7) 01 | INTRODUCTION 02 | FRAME IMPORTANT: Apply BLUE threadlocker to M2 bolts 100-214 and lightly tighten to 10 in-oz torque (finger tight). Replace all 4 bolts after crashing the model. IMPORTANT: Full disassembly is required. Apply RED threadlocker to all swash pivot balls. Heat may be required for removal.
CYCLIC ARMS AND LINKAGES Depending on the flybarless unit and servos chosen, optimal geometry can be achieved using servo arms with ball linkages placed at a distance of 15mm to 17mm from the center of rotation. Rev 1.0M 01 | INTRODUCTION 100-250 M2.5 Regular Nut (3) 02 | FRAME 107-110 Pivot Ball 2.5mm x 4.5mm (3) 03 | LANDING GEAR 107-028 Turnbuckle Link Rod 28mm (3) 107-099 516 Plastic Link (6) For optimal geometry, all servo linkages should be equal in length.
CYCLIC SERVO INSTALLATION Rev 1.0M 100-268 M2.5x8 Socket Head x12 100-274 M2.5 Washer x12 Synergy does not supply with the kit: Servos, servo horns, and servo horn bolts. Apply BLUE threadlocker where indicated. 01 | INTRODUCTION Use care when configuring the flybarless controller to verify servo arms are near or at 90 degrees. Use small trim adjustments if necessary. 02 | FRAME 03 | LANDING GEAR NOTE: The Synergy 516 swash and head geometry has a high cyclic ratio for quick cyclic response.
ANTI-ROTATION GUIDE Apply BLUE threadlocker where indicated. Rev 1.0M Note: Anti-Rotation Mount has threaded holes on the side closest to the main shaft and through holes on the opposite side. Orient correctly! 01 | INTRODUCTION 02 | FRAME 03 | LANDING GEAR 100-266 M2.
TAIL SERVO INSTALLATION Rev 1.0M 01 | INTRODUCTION Use care when configuring the flybarless controller to verify tail servo arm is as close to 90 degrees as possible. 13.5mm servo arm is recommended for optimal tail geometry and throws. 100-254 M2.5 Standard Nut 107-110 Pivot Ball 2.5mm x 4.5mm (3) 02 | FRAME ! 90° 13.5mm Apply BLUE and RED threadlocker where indicated. 03 | LANDING GEAR 04 | BELT TENSION ARM IMPORTANT: Pre-drill servo arm with 2.5mm or 3/32” drill bit before installing Pivot Ball.
TAIL CONTROL ROD Rev 1.0M 01 | INTRODUCTION 107-099 Plastic Link 516-411 Tail Push Rod End 2mm TIP: Insert tail control rod into the tail rod support prior to installing the second linkage. 516-412 Tail Push Rod 525mm 02 | FRAME 03 | LANDING GEAR Use care when configuring the flybarless controller to verify tail pitch arm is 90 degrees at center tail position. 3-5 degrees of pitch compensation against torque is recommended for optimal flybarless behavior.
MAIN HEAD GRIPS IMPORTANT: Full disassembly is required. Apply RED threadlocker to Pitch Arm bolts and pivot balls. Rev 1.0M IMPORTANT: Install Pitch Arm first, then remove any excess threadlocker from inside the grip before installing the bearings. This will prevent contaminating the thrust and radial bearings. 107-110 Pivot Ball 2.5mm x 4.
MAIN HEAD BLOCK ! 606-803 Solid Head Damper Rev 1.0M GREASE COMPONENTS 516-100 Head Block 516-103 Head Axle 01 | INTRODUCTION 02 | FRAME 606-803 Solid Head Damper 305-204 Axle Pivot 03 | LANDING GEAR IMPORTANT: Full disassembly of the head is required. Apply RED threadlocker to both main head axle bolts and tighten firmly. IMPORTANT: Apply threadlocker to inside threads of the Head Axle rather than the Socket Head bolt.
RADIUS ARMS | HEAD INSTALLATION IMPORTANT: Disassembly is required. To prevent damaging bolt 100-316, remove linkage with set screw 100-272 before any disassembly. Rev 1.0M 100-316 M3x16 Socket Head x2 01 | INTRODUCTION 108-383 3x8x3 Radial Bearing (4) 02 | FRAME Apply BLUE threadlocker to all radius arm bolts and set screws. IMPORTANT: Pinch bolts 100-320A should have equal torque applied. Do not overtighten. Apply BLUE threadlocker.
PITCH LINKAGES Turnbuckle linkages have reverse threads on one end. 26 mm length is not final, rather a starting point. The final length may vary. Rev 1.0M TIP: Adjust turnbuckles to achieve proper blade tracking. 01 | INTRODUCTION 02 | FRAME 107-099 Plastic Link (4) Recommended collective pitch range: +/- 12-15 degrees.
MOTOR AND INSTALLATION IMPORTANT: To prevent pinion slippage, verify motor shaft has a flat area where indicated to capture the set screw. Some motors will not have this, use a dremel to add a small flat area. Rev 1.0M 01 | INTRODUCTION IMPORTANT STEPS: 02 | FRAME 108-513 5x13x4 Radial Bearing 03 | LANDING GEAR 04 | BELT TENSION ARM 2. Install the motor and bearing block using the indicated hardware. 05 | MAIN DRIVE 06 | BOOM INSTALLATION 07 | TAIL ASSEMBLY 08 | SETTING BELT TENSION 1.
BATTERY TRAY AND CANOPY NOTE: Apply BLUE threadlocker where indicated. Rev 1.0M TIP: Use CA to secure grommets to canopy. 101-306 M3x6 Button Head (2) IMPORTANT: Remove and apply BLUE threadlocker to BATTERY LOCK HANDLE.
BLADE INSTALLATION Synergy does not include blades in the kit. 100-351 M3 Nylock Nut (2) Rev 1.0M 106-804 Tail Blade Washer (4) 80.6mm Rail tail blades and 516mm Rail main blades are recommended.
COMPLETE MODEL Rev 1.
