Hangar 9 Saratoga 40 User manual

Specications
Wingspan: ........................................................... 64.2 in (1630mm)
Length: ............................................................49.25 in (1251.8mm)
Wing Area: ................................................694 sq in (44.77 sq dm)
Weight: .................................................. 5.5–6.25 lb (2.49–2.83 kg)
Radio: .......................................................4-channel w/4–5 servos
Engine: ..................... .40–52 2-stroke; .56–82 4-stroke; Power 46
Saratoga 40
Assembly Manual

2 Hangar 9 Saratoga Assembly Manual
Table of Contents
Contents of Kit and Parts Layout ......................................2
Included Hardware............................................................3
Using the Manual..............................................................3
UltraCote Covering Colors ................................................3
Before Starting Assembly .................................................3
Radio Systems Requirements...........................................4
Recommended Setup–2-Stroke Glow...............................4
Recommended Setup–4-Stroke Glow...............................4
Recommended Setup–Electric Power (EP).......................4
Field Equipment Required.................................................4
Optional Field Equipment..................................................4
Additional Required Tools .................................................4
Additional Required Adhesives .........................................4
FS One..........................................................................................................................................................4
Important Information Regarding
Warranty Information..................................................4
Landing Gear Installation..................................................5
Tail Installation..................................................................7
Servo Installation..............................................................8
Aileron Servo Installation................................................13
2-Stroke Engine Installation............................................16
4-Stroke Engine Installation............................................20
Cowling Installation ........................................................24
EP Version Motor and Cowling Installation.....................27
\Final Assembly...............................................................31
Optional Float Installation ...............................................32
Center of Gravity.............................................................34
Control Throws ...............................................................34
Flight Preparations..........................................................35
Maintaining Your Model..................................................35
Safety Do’s and Don’ts for Pilots....................................36
Daily Flight Checks..........................................................36
Age requirements............................................................36
Safety, Precautions and Warnings ..................................36
Warranty Information......................................................37
CE Compliance Information for the European Union ......38
2009 Official Academy of
Model Aeronautics Safety Code ................................38
Building and Flying Notes ...............................................39
Replacement Parts
1. HAN4821 Fuselage without hatch
2. HAN4822 Right Wing with Aileron
3. HAN4823 Left Wing with Aileron
4. HAN4824 Tail Set
5. HAN4825 Painted Cowling and Clear Cowling
Template
6. HAN4826 Top Hatch
7. HAN4827 Anodized Wing Tube Set
8. HAN4828 Aluminum Landing Gear
9. HAN4829 Wheel Pant Set (right and left)
10. HAN4830 Windshield
11. HAN4831 Pushrod Set
12. HAN4144 21/4-inch Spinner (yellow)
13. HAN40M Motor Mount: Universal, 40-Size
14. HAN1986 Fuel Tank, 11oz
15. HAN305 23/4-inch H9 wheels
16. HAN4042 Replacement Tailwheel:
.40 Tail Wheel Assembly
17. HAN3611 Nylon Control Horn (5)
18. HAN3610 2-56 Nylon Clevis (5)
19. HAN320 Nylon Wing Bolt, 21/2-inch*
20. HAN8303 Pilot Bust
21. HAN4743 48mm EP Engine Standoff
* Will need to be cut down to 1-inch (25mm) for use with
this model
Contents of Kit and Parts Layout
1
20
19
18
16
17
17
2
3
4
5
6
7
8
9
10
11
12
13
21
14
15

3Hangar 9 Saratoga Assembly Manual
Included Hardware
PACKAGED IN KIT
Fuselage (1)
Left Wing with aileron & control horn (1)
Right Wing with aileron & control horn (1)
Vertical fin with rudder & control horn (1)
Horizontal stab with elevator & control horn (1)
Top hatch (1)
Cowl with clear template (1)
Canopy (1)
Painted aluminum landing gear (1)
Wheel pants (pair) (2)
3/4 x 16-inch anodized wing tube (1)
1/4 x 4-inch anodized wing tube (1)
LANDING GEAR BAG
Float mounting block (1)
Wheel axle, 13/16-inch (2)
Wheel collar, 11/64-inch (4)
3mm x 5mm machine screw for wheel collars (4)
#4 self-tapping wood screw (8)
4-40 x 3/8-inch socket head cap screws (2)
8-32 x 3/4-inch machine screws for landing gear (3)
#8 flat washers for landing gear (3)
Nylon landing gear straps for float mount (4)
Hangar 9 23/4-inch wheels (2)
#4 flat washers (2)
ELEVATOR BAG
Nylon Clevis (1)
Pushrod keeper (1)
Silicone clevis retainer (1)
#4 flat fender washers for bolt-on tail (2)
Nylon insert lock nuts for bolt-on tail (2)
RUDDER BAG
Nylon clevis (1)
Pushrod keeper (1)
Silicone clevis retainer (1)
MOTOR MOUNT BAG
Cast aluminum motor mount (1)
8-32 x 1-inch machine screws (4)
8-32 x 3/4-inch machine screws (4)
8-32 x 21/4-inch machine screws (4)
#8 flat washers (8)
8-32 nylon insert lock nuts (4)
17/8-inch (48mm) EP standoffs (4)
WING BAG
45/8-inch pushrod with L bend (aileron) (2)
1/4-20 x 1-inch nylon wing bolts (2)
Nylon clevis (2)
Pushrod keeper (2)
Silicone clevis retainer (2)
COWL BAG
4-40 x 1/2-inch socket head cap screw for cowl (4)
21/4-inch spinner (yellow) (1)
#4 washers for cowl (4)
Silicone tubing (4)
3mm x 10mm sheet metal screw (2)
FUSELAGE BAG
23-inch pushrod with L bend (elevator) (1)
231/2-inch pushrod with L bend (rudder) (1)
161/2-inch throttle pushrod (1)
Nylon clevis (1)
Pushrod keeper (1)
Silicone clevis retainer (1)
Plywood throttle pushrod support (1)
12-inch throttle pushrod housing (1)
4-40 x 3/8-inch socket head screw (3)
#4 washer (3)
MISCELLANEOUS BAG
Velcro battery strap (2)
1.5mm hex wrench (1)
Foam radio holder (3)
Pilot figure (1)
Using the Manual
This manual is divided into sections to help make assembly
easier to understand, and to provide breaks between each
major section. In addition, check boxes have been placed
next to each step to keep track of each step completed.
Steps with a single box () are performed once, while steps
with two boxes () indicate that the step will require
repeating, such as for a right or left wing panel, two servos,
etc. Remember to take your time and follow the directions.
UltraCote® Covering Colors
• Dark Yellow HANU889
• Black HANU874
• White HANU870
• 2-inch squares, Black/White HANU941
Before Starting Assembly
Before beginning the assembly of your model, remove
each part from its bag for inspection. Closely inspect the
fuselage, wing panels, rudder and stabilizer for damage. If
you find any damaged or missing parts, contact the place of
purchase.
If you find any wrinkles in the covering, use a heat gun or
covering iron to remove them. Use caution while working
around areas where the colors overlap to prevent separating
the colors.
HAN100 – Heat Gun
HAN150 – Covering Glove
HAN101 – Sealing Iron
HAN141 – Sealing Iron Sock

The Spektrum trademark is used with permission
of Bachmann Industries, Inc.
4 Hangar 9 Saratoga Assembly Manual
Radio Systems Requirements
Spektrum Radio System
• DX6i 6-channel radio or greater with receiver
(SPM6600)
• JRPS821 DS821 Digital Sport Servo (5)
(4 required for EP version)
• JSP98110 6-inch Servo Extension (2)
• JSP98020 Y-Harness or JSP98110 6-inch Servo
Extension (2) for receiver to aileron servos
• Receiver Battery, 2700mAh
• Deluxe Chargeswitch (JRPA004)
Optional
• JSP98020 Y-Harness or JSP98110 6-inch
Servo Extension to connect the float rudder
servo to the receiver.
Recommended Setup–2-Stroke Glow
• Evolution® .46NX with Muffler (EVOE0461)
• Evolution Propeller 11 x 5 (EVO11050) to
11 x 6 (EVO11060)
Recommended Setup–4-Stroke Glow
• Saito™.82 AAC w/Muffler (SAIE082AGK or SAIE082A)
• Evolution Propeller 13 x 8 (EVO13080) or
14 x 6 (EVO14060)
Recommended Setup–
Electric Power (EP)
• E-flite®Power 46 BL Outrunner Motor (EFLM4046A)
• 60-Amp Pro Switch-Mode BEC Brushless ESC
(EFLA1060)
• Thunder Power 4S 3850–4500mAh Li-Po Battery Pack
• APC Propeller 13x6.5-inch (APC13065E) to
14x7 (APC14070E)
Field Equipment Required
• Fuel (15% recommended)
• Propeller
• Long Reach Glow Plug Wrench (HAN2510)
• Metered Glow Driver w/Ni-Cd & Charger (HAN7101)
• 2-Cycle Sport Plug (EVOGP1)
• Manual Fuel Pump (HAN118)
Optional Field Equipment
• Selfstick weights, 6 oz (HAN3626)
• PowerPro 12V Starter (HAN161)
• 12V 7Ah Sealed Battery (HAN102)
• Power Panel (HAN106)
• Blue Block After Run Oil (EVOX1000)
• Cleaner and towels
Additional Required Tools
Drill File
Pin drill Pliers
Ruler Scissors
Side cutters Flat blade screwdriver
Medium grit sandpaper Metric propeller reamer
Hobby knife with #11 blade
Phillips screwdriver: #1, #2
Z-bend Pliers (HAN119)
Box wrench to fit propeller nut
Box end or open end wrench: 1/4-inch, 7/16-inch,
1/2-inch
Hex wrench or ball driver: 3/32-inch
Drill bit: 5/64-inch (2mm), 5/32-inch (4mm)
Additional Required Adhesives
Canopy Glue (PAAPT56)
Medium CA (PAAPT02)
Thin CA (PAAPT08)
Zap-A-Dap-A-Goo (PAAPT12)
Threadlock (PAAPT42)
30-Minute Epoxy (HAN8002)
FS One®
With FS One (HANS2000) you get more than photorealistic
fields, gorgeous skies and realistic-looking aircraft. You get
incredibly advanced aerodynamic modeling that simulates
every possible aspect of real-world flight.
The first Hangar Pack (HANS4010) will add even more
aircraft to FS One. This latest edition includes ten new planes
and helis from your favorite brands, including Hangar 9,
E-flite and Align. You’ll be able to fly aircraft that are only
available on FS One such as the T-REX, Blade CX2, Blade CP
Pro, Hangar 9 P-51 and F-22 PTS. And as always, with the
Hangar Pack, you still get all the same great features that
you did with the original aircraft.
HANS2008 HANS4010
Important Information
Regarding Warranty Information
Please read our Warranty and Liability Limitations section on
Page 37 before building this product. If you as the purchaser
or user are not prepared to accept the liability associated
with the use of this Product, you are advised to return this
Product immediately in new and unused condition to the
place of purchase.

5Hangar 9 Saratoga Assembly Manual
Landing Gear Installation
Required Parts
Fuselage Main landing gear
#4 washer (2) #8 washer (3)
Wheel axle with nut (2) Wheel pant (right and left)
4-40 x 3/8-inch socket head screw (2)
11/64-inch wheel collar (4)
23/4-inch (70mm) wheel (2)
3mm x 5mm machine screw (4)
8-32 x 3/4-inch machine screw (3)
Tools and Adhesives
Phillips screwdriver: #2 Threadlock
File
Box wrench: 7/16-inch, 1/2-inch
Ball driver or hex wrench: 3/32-inch
If you are planning to install floats, you can skip the
installation of the fixed gear and begin by attaching the
tail in the following section of the manual.
Step 1
Locate and open the bag marked Landing Gear. In the bag
are the parts for both the land-based landing gear and float
installation. Set aside the forward float mount, four landing
gear straps and eight #4 x 1/2-inch sheet metal screws. Keep
these in case you will be installing the floats at a later date.
Step 2
Locate three 8-32 x 3/4-inch machine screws and three #8
washers. Slide the washers onto the screws.
Step 3
Place a drop of threadlock on each screw. Secure the landing
gear on the fuselage using the three screws and a #2 Phillips
screwdriver.
Step 4
Locate the wheel axle and remove the nut. Slide the threaded
end of the axle into the large hole in the landing gear. Make
sure the axle faces outward. Thread the nut back onto
the axle. Use 1/2-inch (nut) and 7/16-inch (axle) box end
wrenches to tighten the nut to secure the axle.
Note: Make sure the hex on the axle is positioned as
shown or you will have difficulty installing the wheel
pants later.

6 Hangar 9 Saratoga Assembly Manual
Step 5
Use a file to make flat areas on the bottom of the axle. This
is necessary so the setscrews from the wheel collars have
a surface to bite onto. This will help keep the wheel collars
from vibrating loose in flight.
Step 6
Place a drop of threadlock on a 3mm x 5mm machine screw.
Thread the screw into one of the 11/64-inch wheel collars.
Slide the wheel collar onto the axle as shown. Do not tighten
the screw at this time.
Step 7
Open the bag containing the main 23/4-inch (70mm) wheels.
Slide one of the wheels onto the axle. Prepare a second
wheel collar as described in Step 6 and slide it onto the axle.
Position the wheel collar flush with the end of the axle and
use a #2 Phillips screwdriver to tighten the screw, securing
the wheel collar to the axle. The screw will be tightened
down onto the flat made in Step 5.
Step 8
First, slide the wheel against the outer wheel collar. Next
slide the wheel collar next to the landing gear so it is almost
touching the wheel. Use a #1 Phillips screwdriver to tighten
the screw and secure the wheel collar to the axle. The
position of the wheel will be fine-tuned later in this section of
the manual.
Step 9
Slide one of the wheel pants over the wheel and into position
on the landing gear. Note there is a right and left wheel pant
during the installation. Slide a #4 washer onto a 4-40 x 3/8-
inch socket head machine screw. Place a drop of threadlock
on the screw then use a 3/32-inch hex wrench to tighten the
screw, securing the wheel pant to the landing gear.

7Hangar 9 Saratoga Assembly Manual
Step 10
Repeat Steps 4 through 9 to install the remaining wheel and
wheel pant.
Step 11
Position the wheels so ther are centered side to side inside
the wheel pant. You will need to loosen the wheel collasrs
to do so. Also make sure the wheel can rotate freely
without binding.
Hint: Apply a small drop of lightweight oil to help to
allow the wheels to roll smoothly.
Tail Installation
Required Parts
Fuselage assembly Vertical stabilizer
Horizontal stabilizer Nylon clevis
Silicone clevis retainer 4-40 lock nut (2)
#4 fender washer (2) Pushrod keeper
Tools and Adhesives
Box wrench or nut driver: 1/4-inch
Step 1
Locate the bag marked elevator. Use scissors to cut open
the bag and place the parts in a tray for use in assembly.
The clevis and clevis retainer shown will be used later in the
manual when installing the elevator and rudder linkages.
Step 2
Locate the vertical fin and horizontal stabilizer assemblies.
Slide the threaded rods from the vertical fin through the
holes in the horizontal stabilizer. Make sure the control horn
from the elevator faces down, away from the top of the fin/
rudder.
Note: You may need to move the rudder to the left to
allow the rudder control horn the clear the elevator.

8 Hangar 9 Saratoga Assembly Manual
Step 3
Insert the threaded rods from the fin into the holes in the
rear of the fuselage. The tail assembly will sit tight against
the fuselage when installed.
Step 4
Slide a #4 washer on each of the threaded rods. Use a
1/4-inch box wrench or nut driver to tighten the 4-40 lock
nuts on the threaded rods. Use care not to over-tighten the
nuts and accidentally crush the fuselage.
Servo Installation
Required Parts
Fuselage assembly Servo (3, 2 for electric)
Hook and loop strap Receiver
Receiver battery Switch harness
Foam padding Pushrod keeper (2)
Clevis (2) Clevis retainer (2)
231/2-inch (597mm) pushrod wire
23-inch (584mm) pushrod wire
Y-Harness (1) or 6-inch (152mm) servo extension (2)
Tools and Adhesives
Phillips screwdriver: #1 Thin CA
Scissors Ruler
Hobby knife with #11 blade Pin drill
Drill bit: 5/64-inch (2mm) Pliers
Step 1
Insert the rubber grommets and brass eyelets into the
servos. Prepare three servos (two for electric-powered
model) at this time.

9Hangar 9 Saratoga Assembly Manual
Step 2
Use a #1 Phillips screwdriver to thread the servo mounting
screws into the pre-drilled holes in the servo tray then
remove the screw. Apply 2–3 drops of thin CA into each of
the holes to harden the surrounding wood.
Step 3
Use a #1 Phillips screwdriver to install the screws that hold
the servos in position in the fuselage. If you are building the
electric version, you do not have to install the throttle servo.
Note the direction of the servos in the image below. Route
the leads from the servos forward into the receiver/receiver
battery compartment.
Step 4
Open the bag marked Miscellaneous. Remove one of the
hook and loop straps and insert it through the strap supports
inside the fuselage.

10 Hangar 9 Saratoga Assembly Manual
Step 5
Measure and cut a 31/4-inch piece of foam from the supplied
foam blocks using scissors.
Step 6
Move the servo leads away from the battery compartment
and back over the servos. Insert the piece of foam into the
battery compartment. Make sure the hook and loop strap is
centered after installing the foam as shown in the photo.
Step 7
Use a hobby knife with a #11 blade to remove the covering
from your particular switch mounting hole. Mount the
switch in the fuselage using the hardware provided with
your switch.
Step 8
Place the receiver battery in the fuselage, then place the
remaining piece of foam on the battery. Make sure to plug
the battery into the switch harness at this time.
Step 9
Plug the servos, extension(s) or Y-harness for the aileron
servos and the switch harness into the receiver.
Step 10
Place the receiver on the foam. Tuck all the servo leads
under the servo tray so they will not interfere with the
operation of the servos.

11Hangar 9 Saratoga Assembly Manual
Step 11
Cut a 31/4-inch piece of foam from the supplied foam blocks
using scissors from the second large blank as instructed in
Step 5. Place the foam on the receiver, then use the hook
and loop strap to secure the position of the receiver and
receiver battery. Mount the remote receiver forward in the
fuselage as shown.
Note: The antenna on the main receiver must be kept
90 degrees to the receiver. Make sure the foam does not
bend the antenna down or the range of the radio may be
reduced.
Step 12
Use a #1 Phillips screwdriver to remove the servo horns
from the elevator and rudder servos.
Step 13
With the radio system on, center the rudder and elevator
servos. Make sure all sub-trims (if using a computer radio)
have been set to 0. Install a 180-degree servo arm on the
rudder and elevator servos so they are perpendicular to the
fuselage centerline.
Step 14
Use a pin drill and 5/64-inch (2mm) drill bit to enlarge the
hole in the servo arm that is 9/16-inch (15mm) from the
center of the servo arm as shown in the photo below.
Step 15
Open the bag marked Fuselage and remove the two longer
pushrod wires. Insert the longer 231/2-inch (597mm)
pushrod wire into the tube inside the fuselage that exits at
the rudder control horn. The remaining 23-inch (584mm)
pushrod wire is then inserted in the tube that will exit near
the elevator control horn.

12 Hangar 9 Saratoga Assembly Manual
Step 16
Insert the bent end of the pushrod wires into the holes in the
servo arms that were enlarged back in Step 14. The wires
will go into the holes from the top side of the servo arm.
Step 17
Slide the pushrod keeper onto the pushrod wire from
underneath the servo. Rotate the keeper and snap it onto the
pushrod wire using pliers to secure the pushrod wire to the
servo horn.
 Step 18
Install a pushrod keeper to secure the rudder and elevator
pushrods at this time.
 Step 19
Slide a clevis retainer on a clevis. Thread the clevis on the
elevator pushrod a few turns so it will not fall off.

13Hangar 9 Saratoga Assembly Manual
Step 20
With the radio system on, thread the clevis on the elevator
pushrod so the elevator is in alignment with the stabilizer
when the clevis is attached to the center hole of the control
horn. Use a ruler to verify the alignment between the
stabilizer and elevator. Make sure to slide the clevis retainer
onto the clevis prevent it from opening accidentally
Step 21
Repeat Steps 18 and 19 to connect the rudder pushrod to
the center hole of the rudder control horn.
Aileron Servo Installation
Required Parts
Wing panel (right and left) Servo w/hardware (2)
Clevis (2) Clevis retainer (2)
Pushrod keeper (2)
45/8-inch (117mm) pushrod wire
6-inch (152mm) servo extension (2)
Tools and Adhesives
Phillips screwdriver: #1 Thin CA
Drill bit: 5/64-inch (2mm) Pin drill
 Step 1
Insert the rubber grommets and brass eyelets into the
servos. Prepare two servos at this time. Secure a 6-inch
(152mm) servo extension to the servo lead of the aileron
servo using string or a commercially available connector.

14 Hangar 9 Saratoga Assembly Manual
 Step 3
Use a #1 Phillips screwdriver to thread a servo mounting
screw into each of the holes, then remove the screw.
Apply a drop or two of thin CA in each hole to harden the
surrounding wood.
 Step 4
A string has been pre-installed in the wing so the servo lead
and extension can be pulled through the wing. Remove the
tape to expose the end of the string at the servo opening. Tie
the string around the servo extension so it can be pulled to
the center of the wing.
 Step 5
Use the string to pull the servo extension to the center of
the wing. Once at the center, guide it through the hole on the
bottom of the wing as shown in the photo.
 Step 6
Place the servo into the opening with the output of the servo
facing the aileron. Use the four screws provided with your
servo and a #1 Phillips screwdriver to secure the servo in
the wing.
 Step 7
Use a pin drill and 5/64-inch (2mm) drill bit to enlarge the
hole in the servo arm that is 9/16-inch (15mm) from the
center of a 180-degree servo arm as shown.
 Step 8
Use a #1 Phillips screwdriver to remove the original servo
arm from the aileron servo. After using the radio system to
center the aileron servo, install the 180-degree servo arm as
shown. Make sure the servo horn is parallel to the aileron
hinge line when it is installed.

15Hangar 9 Saratoga Assembly Manual
 Step 9
Open the bag marked wing. Insert the bent end of the 45/8-
inch (117mm) pushrod wire into the outer hole of the servo
as shown. The wire will be on the side of the servo horn that
is closer to the wing tip.
 Step 10
Slide the pushrod keeper onto the bend from the underside
of the servo horn. The keeper will then be rotated and
snapped onto the pushrod wire to secure the wire to the
servo arm.
 Step 11
Slide the clevis retainer onto the clevis. Thread the clevis on
the pushrod wire a few turn to get it started and secure.
 Step 12
With the radio system plugged in and on, check that the
aileron servo is centered. Thread the clevis on the pushrod
wire so when the clevis is connected to the center hole of the
control horn the aileron is centered and in alignment with the
trailing edge of the wing. Once the adjustments have been
made, make sure to slide the clevis retainer onto the clevis
so it will not open accidentally.
Step 13
Repeat Steps 1 through 12 to install the remaining aileron
servo and linkage.

16 Hangar 9 Saratoga Assembly Manual
2-Stroke Engine Installation
Required Parts
Fuselage assembly Engine with hardware
Engine mount Engine mount plate (2)
#8 washer (8) 8/32 lock nut (4)
Plywood pushrod support Clevis
Clevis retainer Pushrod keeper
8-32 x 1-inch machine screw (4)
8-32 x 3/4-inch machine screw (4)
161/2-inch (419mm) throttle pushrod wire
12-inch (305mm) throttle pushrod housing
Tools and Adhesives
Phillips screwdriver: #2 Threadlock
Medium grit sandpaper Ruler
Side cutters Pliers
Drill bit: 5/64-inch (2mm) Pin drill
Medium CA 30-minute epoxy
Step 1
Open the bag marked Motor Mount. Set aside the four
48mm standoffs and four 8-32 x 21/4-inch machine screws
for the Electric Power (EP) version as they will not be used
in the engine installation.
Step 2
Slide a #8 washer onto each of the 8-32 x 3/4-inch machine
screws. Apply a drop of threadlock on each screw.
Step 3
Slide the screws into the motor mount as shown.
Step 4
Attach the mount to the fuselage using the screws prepared
in the previous step and a #2 Phillips screwdriver. Use
30-minute epoxy to seal the seams for the EP air inlet
firewall plugs as shown.
Note: Blind nuts have been installed for both the glow
and EP versions. Make sure to install the mount at an
angle as shown. The hardware for the glow mount will
not match up to the EP blind nut installation.
Step 5
Slide a #8 washer onto an 8-32 x 1-inch machine screw.
Slide the screw through the engine mount plate as shown.
Prepare two plates: one right and one left at this time.

17Hangar 9 Saratoga Assembly Manual
Step 6
Insert the screws in the holes toward the firewall. Note that
the arches on the engine mount plates face to the centerline
of the fuselage. Thread an 8-32 lock nut on each screw. Do
not tighten the nut: simply thread it on until the screw hits
the nylon insert in the nut.
Step 7
Lift the engine mount plates up and position the engine so
the mounting lugs on the engine are between the engine
mount and engine mount plates. Position the engine so the
front of the drive washer is 49/16 inches (115mm) forward of
the firewall.
Step 8
Locate the last two 8-32 x 1-inch machine screws, #8
washers and 8-32 lock nuts. Slide a washer on each screw
and then pass the screw through the engine mount plate and
engine mount. Thread the lock nut onto the screw.
Step 9
Using a #2 Phillips screwdriver, tighten the screws evenly to
clamp the engine in position on the engine mount.
Step 10
Use a piece of medium grit sandpaper to roughen a 2-inch
(52mm) section on each end of the 12-inch (305mm)
throttle pushrod housing. This is necessary for the CA to
stick to the tube when it is installed in the fuselage.
Step 11
Slide the pushrod housing into the hole in the firewall and
into the fuselage. Leave roughly 11/4-inch (32mm) of the tube
forward of the firewall. Do not glue the tube at this time.

18 Hangar 9 Saratoga Assembly Manual
Step 12
Slide the plywood pushrod support on the tube inside the
fuselage. Do not glue the support or tube at this time.
Note: The plywood pushrod support will be glued in
position after the fuel tank has been installed.
Step 13
Slide a clevis retainer on the clevis. Thread the clevis
12 turns onto the 161/2-inch (419mm) throttle pushrod
wire. Slide the wire into the tube near the engine.
Step 14
Connect the clevis to the outer hole of the carburetor arm as
shown.
Step 15
Move the carburetor and pushrod to the closed position.
Use the radio system to move the throttle servo to the low
position. Use a felt-tipped pen to mark the pushrod where it
crosses the servo arm as shown.
Step 16
Use the radio system to move the throttle servo to the
fully open position. Move the throttle pushrod to move the
carburetor to the fully open position. Check that the mark
made in the last step is still aligned with the hole in the
servo arm used in the last step, or be very close. If not, use
isopropyl alcohol to remove the mark. The goal is to have
the mark align with the same hole in the servo arm at both
the open and closed positions. You may need to remove the
arm and rotate it to choose other holes in the servo arm for
this to happen. If you are using a computer radio you can
also use the ATV function to adjust the throttle throw.

19Hangar 9 Saratoga Assembly Manual
Step 17
Once the pushrod has been marked, use pliers to bend the
pushrod wire 90 degrees at the mark. Use side cutters to
trim the pushrod wire 3/8-inch (10mm) from the bend.
Step 18
Use a pin drill and 5/64-inch (2mm) drill bit to enlarge
the hole in the servo arm for the pushrod wire to fit into.
Remove the servo arm and use side cutters to remove any
unused arm so they will not interfere with the operation of
the throttle servo.
Step 19
Insert the bend on the pushrod wire into the hole of the
servo arm. Slide the pushrod keeper on the wire then rotate
it so it secures the connection between the pushrod and
servo arm.
Note: The bend on the pushrod wire goes up through
the servo arm to prevent any binding between the
pushrod wire, connector and servo.
Step 20
Use the radio to move the throttle to the closed position.
Move the pushrod to close the carburetor and attach the
servo horn back on the throttle servo.

20 Hangar 9 Saratoga Assembly Manual
Step 21
Check the operation of the throttle from the radio to make
sure it goes from fully closed to fully open, and that the
servo is not binding at either endpoint as well. If you are
using a computer radio, use the endpoint adjustments
as necessary to fine-tune the operation of the throttle if
necessary.
4-Stroke Engine Installation
Required Parts
Fuselage assembly Engine with hardware
Engine mount Engine mount plate (2)
#8 washer (8) 8/32 lock nut (4)
Plywood pushrod support Clevis
Clevis retainer Pushrod keeper
8-32 x 1-inch machine screw (4)
8-32 x 3/4-inch machine screw (4)
161/2-inch (419mm) throttle pushrod wire
12-inch (305mm) throttle pushrod housing
Tools and Adhesives
Phillips screwdriver: #2 Threadlock
Medium grit sandpaper Ruler
Side cutters Pliers
Z-bend pliers Medium CA
30-minute epoxy
Drill bit: 5/64-inch (2mm), 5/32-inch (4mm)
Step 1
Open the bag marked Motor Mount. Set aside the four
48mm standoffs and four 8-32 x 21/4-inch machine screws
for the Electric Power (EP) version as they will not be used
in the engine installation.
Step 2
Slide a #8 washer onto each of the 8-32 x 3/4-inch machine
screws. Apply a drop of threadlock on each screw.
Step 3
Slide the screws into the motor mount as shown.