Avantco Aurora Ultimate 90 User manual

2AVANT Aurora Ultimate 90 Assembly Manual
AVANT Aurora Ultimate 90
Assembly Manual V1.08
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
operation, maintenance or assembly can potentially cause a helicopter to
pose a danger to persons or objects including but not limited to the
possibility of causing serious physical injury and even death. This product
is intended to be used by experienced adult radio control helicopter pilots
under controlled safety conditions and on locations properly authorized
and setup for safe flying and away from other people. Under no
circumstance should a minor be allowed to operate this or any radio
controlled helicopter without the approval, supervision and direction of his
parent or legal guardian who takes full responsibility for the minor's
actions. Do not operate an RC helicopter within the vicinity of homes,
trees, electrical lines during inclement weather or rain or near crowds of
people. After leaving its facilities the manufacturer has no way of
maintaining control or supervision over the assembly and/or operation of
the helicopter.
The manufacturer and/or its agents assume no responsibility or liability
whatsoever for any damages including but not limited to ones generated
by incidental or consequential damages.
The operator of the helicopter assumes all responsibility and liability that
could be result from the correct or incorrect operation of the helicopter.
Symbols:
Important, &Correct, 'Incorrect, 1Danger, ¥Allow it to set for some time before
continuing
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

AVANT Aurora Ultimate 90 Assembly Manual _3
 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.
Important: Using a piece of #400 sanding paper sand the edges of the carbon fiber pieces
that will be close to any electronic wires or fuel tubing. Sharp edges can cut into the electric
wires and since carbon fiber is conductive it can possibly create an electrical shortcut. Sharp
edges can also cut fuel tubing creating leaks that could make the engine operation fail.
Whenever you’re ready to install a carbon fiber piece that will be close to servo wiring make
sure to sand its edges to prevent wire chafing and a possible electrical short circuit.
Bag #1: Left Frame assembly, Motor Mount Center and Gyro Mount.
A
V00-200-625 (Short)
M3x8 (1) AV00-100-421
M3 Locknut (2) AV00-100-320
M3 Locknut (2) AV00-100-320
A
V00-200-624 (Long)
M3x8 (2)
AV00-100-421
Install the back sacrificial breakout tab
AV00-200-262
M3x8 (2)
AV00-100-421
AV00-200-511
Install the front canopy mount
M3x8 (1) AV00-100-421
AV00-200-511 Sacrificial Breakout Tab
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

4AVANT Aurora Ultimate 90 Assembly Manual
M3x8 (2) AV00-100-421 AV00-100-604
AV00-100-604
A
V00-200-504
Install five 26mm spacers
M3x8 (1) AV00-100-421
AV00-100-604
M3x8 (3) AV00-100-421
stubs and two 5mm long grommets
M3x8 (2)
A
V00-200-744
A
V00-100-683
M3x8 (2) AV00-100-421
Cut the rubber strip into ten 10mm long.
You will use half of them on the left frame
and the other half on the right frame. Using
CA glue install the tank rubber mounts
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

AVANT Aurora Ultimate 90 Assembly Manual _5
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 M3x6 Button Head (6) AV00-100-441
M2.5 washer (6) AV00-100-301
AV00-200-738
AV00-200-737
AV00-200-291
AV00-200-669  NOTE:
Previous version
used flat head
screws instead
of button head.
AV00-200-678
Using six M2.5x8 screws
install the Main gear onto the
pre-assembled main gear
hub
Using six M3x6 button head screws
install the constant drive gear onto
the constant drive hub.
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

6AVANT Aurora Ultimate 90 Assembly Manual
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.
Slide the Main Shaft into the main gear
assembly and install the hardened pin
that locks the constant drive hub into the
main shaft and screw the M6x10
setscrew into the bottom of the main
shaft to secure the pin in place, There is
no need to over tighten this setscrew.
Slide the top bearing blocks and the
bottom bearing block oriented as
indicated by the small notched facing the
back. Notice that the small notches for
the entire bearing block should be facing
the rear side of the heli.
AV00-200-676 (Sharp edge should point toward the sleeve)
AV00-200-671
AV00-200-680
AV00-100-613
Open bearing side
faces up
Open bearing side
faces down
Open bearing side
faces up
Small notch faces
back M6x10mm AV00-100-355 Main
shaft pin retainer setscrew
Small notch faces
back AV00-100-613
AV00-100-333
Main shaft pin
 IMPORTANT NOTE: Use
Blue Loctite on the mainshaft
pin itself.This will prevent it
from sliding out even if the
setscrew becomes lose.
 IMPORTANT NOTE: Pay attention to
the orientation of the bearing blocks.
The top block open bearing side should face
up, the mid one should face down and the
bottom one should face up.
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

AVANT Aurora Ultimate 90 Assembly Manual _7
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.
This is the main means of holding the main
shaft in place so no play should be allowed.
While holding the pressure described
above install the M3x8 screws that hold
the top and mid bearing blocks in place.
Notice that one of the M3x8 screws
is a button (round) head screw.
Proceed now to install the side stiffener plate
by using the spacers and screws provided.
M3x8 (1) Button (Round)
Head AV00-100-442
M3x8 (3)
AV00-100-421
AV00-100-610
AV00-100-611
AV00-100-612
M3x20 (2) AV00-100-426
AV00-200-509
M3x25 (1) AV00-100-427
M3x25 (2) M3x20 (2)
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

8AVANT Aurora Ultimate 90 Assembly Manual
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Bag #3: Clutch Stack, Clutch Bell assembly.
M3x6 (2) AV00-100-420
AV00-200-506 Ratio plate
Install the gear ratio plate making sure that
the notch points toward the back of the helicopter.
AV00-200-472
M4x4 (1)
AV00-100-351
AV00-200-602
AV00-200-609
AV00-200-309
AV00-200-605
AV00-100-613
AV00-200-604
AV00-200-606
M3x10 (4) AV00-100-422
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. You can use masking tape around
the clutch and use it as a plug to push the liner against the
bell wall while it’s curing. Assemble the clutch bell stack as
shown on the left.
Use red Loctite to lock the pinion into the
inner race of the pinion’s bearing block. Use Blue
Loctite to secure the pinion nut into the pini
on.
AV00-200-619
Install the assembly on the left frame using the
supplied M3x10 screws to bolt the two bearing blocks.
Don’t tighten them now wait until the engine is
installed to let the starter shaft fit in the clutch first.

AVANT Aurora Ultimate 90 Assembly Manual _9
Bag #4: Tail Pickup gear mechanism and gear meshing method.
6mm Shim
AV00-100-331
AV00-200-721
AV00-200-618
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.
Assemble the torque input shaft
assembly as shown. The
spacing
between the blocks is set by the
holes in the frames.
6mm Shim
AV00-200-619 (2)
M3x4 (1)
AV00-100-350
AV00-200-726
AV00-100-330
Install the two assemblies into the frame as
shown. Don't tighten the collar or the 2.5mm
dog-bone pin and setscrew until they are
placed in the frames and the mesh is
checked for no play at all and flush
alignment of the inner face of the teeth on
both gears.
You need to replace the 6mm id bearing spacers until
there is no play between the bevel gears. Follow the
instructions shown in the next pages for the gear mesh.
M3x8 (8) AV00-100-421
A
V00-100-332
M3x4 (1)
AV00-100-350
M3x4 (1)
AV00-200-608
AV00-200-307 - 6mm ID x 0.1mm Shim
AV00-200-308 - 6mm ID x 0.2mm Shim
AV00-200-309 - 6mm ID x 0.3mm Shim
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

10 AVANT Aurora 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). The
Aurora has a large window to inspect the gears inside the frames as well as the ones inside
the tailcase.
Frame inspection window. Tailcase inspection window.
There are three things that need to be assured for a correct mesh in the Aurora: Flush
alignment, No Play and Lubrication.
1) Flush alignment: Make sure that the gears are aligned so that the inner side of the teeth
are in the same plane flush to each other at the point of contact.
2) No Play: Make sure there is no play between the gears.
3) Lubrication: Make sure to lubricate the gears with a few drops of fuel before each flying
day letting the alcohol evaporate leaving the fuel's oil as lubricant.
1) Flush Alignment:
In order to illustrate how to achieve it here's a couple of pictures of gears aligned incorrectly
followed by a couple of pictures of correctly aligned ones.
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

AVANT Aurora Ultimate 90 Assembly Manual _11
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
Wrong alignment case #1:
Top gear too forward
Wrong alignment case #2:
Bottom gear too forward

12 AVANT Aurora Ultimate 90 Assembly Manual
Correct tooth face alignment:
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite
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),
(0.3+0.2), (0.3+0.2+0.1). In order
to align them flush you simply
select thinner washer shims for the
one that's too forward or thicker
for the one that's not forward
enough.

AVANT Aurora Ultimate 90 Assembly Manual _13
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. There should be no movement on the
gear. If there is movement simply increase the thickness on BOTH shafts the SAME amount
so that the flush alignment from step 1 is not lost and try again.
Once set as described it'll take a few flights for the gears to set and break in.
3) Lubrication:
The same oil that will be left as residue from your flight session is used as lubricant. At the
beginning of the flight day drop a few drops of fuel rotate the main rotor a few turns and let
the alcohol evaporate for a couple of minutes leaving the oil residue for lubrication.
Remember the three steps:
1) Flush alignment
2) No Play
3) Lubrication
Bag #5: Battery / Radio Plate
AV00-200-730
AV00-200-730 AV00-200-508
M3x10 (2) AV00-100-422
M3x8 (2) AV00-100-421
Install battery blocks on the frames
and then the battery/radio plate on
them.
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

14 AVANT Aurora Ultimate 90 Assembly Manual
M3x8 (1)
M3x8 (1) AV00-100-421
M3 Locknut (2)
M3x8 (2)
A
V00-200-624 (Long)
M3x6 (2)
A
V00-100-420
A
V00-200-506
A
V00-200-505
A
V00-200-625
(Short)
M3x8 (2)
AV00-100-421
A
V00-200-511
M3 Locknut (2)
AV00-100-320 Bag #6: Right Frame,
frame bellcrank and Tail
boom clamp.
Install the sacrificial tabs
and canopy mount posts as
previously done in the left
frame as well as the gear
ratio plate as shown in the
picture. Make sure the
plate's notch is facing back
toward the rear of the
helicopter. Install the tank
rubber mounts the same
way as explained before on
step 01.
Install the right frame onto the left side assembly as shown below.
Do not tighten
the four M3x10mm
screws in the ratio
plate until the engine
is installed and the
clutch stack is aligned
with the en
g
ine.
M3x8 AV00-100-421 M3x10 (4)
A
V00-100-422
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

AVANT Aurora Ultimate 90 Assembly Manual _15
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)
A
V00-100-320
A
V00-200-753
M3 washer (4)
A
V00-100-302
Assemble the tail frame
bellcrank as shown.
A
V00-200-723 Tail
Bellcrank strai
g
ht Note: Boomclamp installation is
better left for the end when the boom is
ready for installation. Remember not to
tighten the clamps excessively or you
A
V00-200-260
A
V00-200-302
A
V00-200-667
could crack the carbon boom.
Bag #7: CCPM System and Swashplate
Start the thread by
using an M2 screw from
the bag that contains the
tailcase. Use Blue Loctite
in the screw. Apply the
same method for all M2
threads that go into plastic M3 Washer
AV00-100-619
M2.5x8 (1)
A
V00-100-410
M2.5 washer (1)
AV00
-
100
-
301
AV00-100-617
AV00-100-621 (Short)
AV00-200-667
M4x4 (1) Cup AV00-100-357 AV00-100-635
M3x18 (1) AV00-100-425
1mm bearing spacer
A
V00-200-301
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

16 AVANT Aurora Ultimate 90 Assembly Manual
M4x4 (1) Cup point Setscrew
AV00-100-357
AV00-100-618
AV00-200-667
AV00-100-619
AV00-100-622 (Long)
M4x4 (1) Cup point
Setscrew AV00-100-357
AV00-100-620
A
V00-100-624
A
V00-200-620
A
V00-200-668 (7)
Install the seven balls and the guide pin on
the pre-assembled swashplate as shown.
M3x4 (3) AV00-100-350 Setscrew
Install three into the swashplate and don’t over
tighten them. Tighten them as needed to
eliminate
p
la
y
as the bearin
g
wears with use.
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

AVANT Aurora Ultimate 90 Assembly Manual _17
Slide the Swashplate onto the main
shaft and install the CCPM guide with
the four screws as shown.
M3x8 (4)
A
V00-100-421
A
V00-200-733 Install AV00-200-621 Main Shaft Collar
using two M4x4 (2) Flat AV00-100-351
Bag #8: Fan hub, Fan, Clutch and motor mount sides
A
V00-200-607
A
V00-200-740
M3x8 (4) Button (round) Head AV00-100-442
If using a governor install the magnet into the fan with
epoxy. Attach the fan to the fan hub with the four
round head screws then install the fan hub into the
engine by tightening the fan into the threaded
crankshaft. Lock the engine crankshaft in place by
using an engine lock from the back of the engine and
locking the piston rod in place. Once the fan is
tightened in place use the engine's washer and nut to
lock the fan in place. In most cases the engine washer
is not used. If you use the engine washer make sure
the clutch doesn’t bind against the clutch bell.
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

18 AVANT Aurora Ultimate 90 Assembly Manual
o
Install the clutch using the two M4
screws provided. Use blue Loctite to
secure them.
Insert the engine in place by
making the starter shaft fit into
the clutch one-way bearing. Use
blue Loctite to install the four
M4 screws provided that hold
the motor mount sides in place.
Use blue Loctite to install the
four M4 screws provided that
hold the engine in place. If
using a governor also install the
sensor plate. Use the location of
the sensor plate to mark the
location in the fan shroud so an
opening can be made in the fan
shroud to allow for the sensor t
clear.
AV00-200-603
AV00-200-290 One-way Bearing
M4x14 (4) AV00-100-433 AV00-100-608 M4x16 (4)
AV00
-
100
-
434
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 sli
p
.
M4x8 (2) AV00-100-430
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

AVANT Aurora Ultimate 90 Assembly Manual _19
Bag #9: Fan shroud installation
Insert both fan shroud sides in place
Install the fan shrouds in place. In
order to insert them in place there are
notches in the back side that allow for
an easier insertion. Once located in
place use the four M3x10 screws
provided to secure them in place.
A
V00-200-734
M3x10 (4) AV00-100-422
A
V00-200-734
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.
M3x8 (6) AV00-100-421
Join the two fan shroud halves
using the six M3x8 screws
provided.
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite

20 AVANT Aurora Ultimate 90 Assembly Manual
sing the provided hardware
o to
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
reference to space them
approximately where they go.
Insert the four M3x5 setscrews
but don't tighten them
completely until the assembly is
installed on the helicopter.
M3x5 (4) AV00-100-358
AV00-200-722
M3 wa
M3x10 (4)
A
V00-100-422
sher (4)
A
V00-100-302
M3 locknut (4)
U
install the back landing gear
struts on the frames as
shown. You might need t
squeeze the frames inward
make the struts fit.
A
V00-100-320
Note: Unless indicated otherwise all screws, balls and threads are installed with Blue Loctite