JR ProPo Ergo Z230 User manual

ASSEMBLY INSTRUCTIONS
Also for use in assembly of JR Ergo Quattro when combined with Ergo Quattro Suppliment Instructions.
Heli Division
ERGO Z230 SPECIFICATIONS
Overall Length 55.85"
Overall Height 18.92"
Main Rotor Diameter 60.45"
Tail Rotor Diameter 10.34"
Gear Ratio 6.77:1:5.18
Gross Weight 12.4 lbs.

INTRODUCTION
Congratulations on your purchase of the JR Ergo helicopter kit.
This kit has been both engineered and manufactured by JR with help from some
of Japan’s top R/C helicopter engineers (now employed by JR).
As you may well know, the name JR has for years been synonymous with state-
of-the-art, high quality radio control systems known the world over for their
exceptional reliability and engineering.
JR now brings this reputation and knowledge into the helicopter market with the
development of the Ergo and the organization of the JR heli division. Years in the
making, the Ergo’s superior quality and exceptional parts fit and finish create a
new standard of quality that was previously unavailable.
Before you begin the assembly of your Ergo, we suggest that you first review the
entire instruction manual to become familiar with the assembly sequences and
parts layout.
WARNING
The radio controlled model helicopter contained in this kit is not a toy, but a
sophisticated piece of equipment. This product is not recommended for use by
children. Radio controlled models such as this are capable of causing both
property damage and/or bodily harm to both the operator/assembler and/or
spectator if not properly assembled and operated. Horizon Hobby Distributors
assumes no liability for damage that could occur from the assembly and/or
use/misuse of this product.
AMA INFORMATION
We strongly encourage all prospective and current R/C aircraft pilots to join the
Academy of Model Aeronautics. The AMAis a non-profit organization which
provides services to model aircraft pilots. As an AMA member, you will receive a
monthly magazine entitled Model Aviation, as well as a liability insurance plan to
cover against possible accident or injury. All AMA charter aircraft clubs require
individuals to hold a current AMA sporting license prior to operation of their
models. For further information, you can contact the AMA at:
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302
[phone]
PRE-ASSEMBLY INFORMATION
Since this manual has been formatted for use in assembly of both the Ergo Z230
and the Ergo Quattro, near each assembly step number you will notice the
following symbols:
Please refer to these symbols to guide you in the specific assembly of your
particular model.
When first opening your Ergo kit, you will notice that all of the parts are
packaged and numbered to coordinate with the assembly step numbers of this
instruction manual.
All small hardware (nuts, bolts, washers, etc.) for each step are separated and
packaged separately within the main parts bags. When beginning a section, you
will need to open only the bag with the corresponding number to the section you
are going to start. It is suggested that you place all of the hardware in an open
container (e.g., coffee can) during assembly so as not to lose any of the small
parts. It may also be helpful to familiarize yourself with the various sizes of
screws, bolts, nuts, etc., as illustrated in the appropriate assembly section before
you begin assembly. At the end of each assembly, in most cases, there should be
no parts remaining.
Great care has been taken in filling the bags with the correct quantity of parts and
hardware for each section. However, occasionally mistakes do happen. In the
event that you find a parts shortage or are in need of technical assistance, please
contact your local JR heli division parts dealer, or contact the Horizon Service
Center directly.
Horizon Service Center
4105 Fieldstone Road
Champaign, IL 61821
[phone] (9am to 5pm CST)
2
Z
Q
Z,Q
For use in assembly of Ergo Z230 only
For use in assembly of Ergo Quattro only
For use in assembly of both Ergo Z230
and Ergo Quattro

3
Building Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Tools/Field Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1-1 Clutch Bell/Start Shaft Assembly . . . . . . . . . . . . . . . . . . . .8
1-2 Tail Drive Pinion/Bearing Block Assembly . . . . . . . . . . . .8
1-3 Control Ball Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1-4 Servo Mixing Lever Unit Assembly . . . . . . . . . . . . . . . . .9
1-5 Elevator Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .10
1-6 Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2-1 Upper Main Frame Section Assembly . . . . . . . . . . . . . . .12
2-2 Upper Main Frame Control Lever Installation . . . . . . . . .13
2-3 Lower Main Frame Assembly . . . . . . . . . . . . . . . . . . . . .14
2-4 Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2-5 Front Radio Bed Installation . . . . . . . . . . . . . . . . . . . . . . .15
2-6 Cooling Fan Shroud Installation . . . . . . . . . . . . . . . . . . . .15
2-7 Upper/Lower Main Frame Assembly Attachment . . . . . .16
3-1 Main Drive Gear/Autorotation Assembly . . . . . . . . . . . . .17
3-2 Main Drive Gear/Autorotation Assembly Installation . . .17
3-3 Landing Gear Assembly Installation . . . . . . . . . . . . . . . .18
3-4 Engine Preparation/Cooling Fan Installation . . . . . . . . . .18
3-5 Clutch Assembly Attachment . . . . . . . . . . . . . . . . . . . . . .19
3-6 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3-7 Muffler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3-8 Carburator/Aircleaner Assembly Installation . . . . . . . . . .20
4-1 Rotor Head Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . .21
4-2 Main Blade Holder Assembly . . . . . . . . . . . . . . . . . . . . . .21
4-3 Main Blade Holder/Seesaw Attachment . . . . . . . . . . . . . .22
4-4 Seesaw Mixing Arm Installation . . . . . . . . . . . . . . . . . . .22
4-5 Washout Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .23
4-6 Tail Pitch Slide Ring Assembly . . . . . . . . . . . . . . . . . . . .23
4-7 Swashplate/Washout Assembly Installation . . . . . . . . . . .24
4-8 Rotor head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4-9 Flybar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4-10 Flybar Paddle Attachment . . . . . . . . . . . . . . . . . . . . . . . .26
4-11 Rotor Head/Swashplate Control Rod Installation . . . . . . .27
5-1 Tail Output Shaft/Pulley Assembly . . . . . . . . . . . . . . . . .28
5-2 Tail Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . .28
5-3 Tail Center Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . .29
5-4 Tail Blade Holder Assembly . . . . . . . . . . . . . . . . . . . . . . .29
5-5 Tail Pitch Control Lever Installation . . . . . . . . . . . . . . . .30
5-6 Tail Boom Carrier Installation . . . . . . . . . . . . . . . . . . . . .30
5-7 Tail Boom Assembly Installation . . . . . . . . . . . . . . . . . . .31
5-8 Vertical Fin Attachment . . . . . . . . . . . . . . . . . . . . . . . . . .31
5-9 Tail Boom Brace Assembly . . . . . . . . . . . . . . . . . . . . . . .32
5-10 Tail Boom Brace/Horizontal Fin Installation . . . . . . . . . .32
6-1 Upper Servo Tray Installation . . . . . . . . . . . . . . . . . . . . . .33
6-2 Servo/Switch Harness Installation . . . . . . . . . . . . . . . . . .34
6-3 Tail Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . .35
6-4 Tail Control Rod Installation . . . . . . . . . . . . . . . . . . . . . .35
6-5 Gyro/Receiver/Battery Installation . . . . . . . . . . . . . . . . . .36
Radio System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7-1 Aileron Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
7-2 Elevator Linkage Installation . . . . . . . . . . . . . . . . . . . . . .38
7-3 Collective Pitch Linkages . . . . . . . . . . . . . . . . . . . . . . . . .39
7-4 Tail Control Rod Servo Connection . . . . . . . . . . . . . . . . .39
7-5 Throttle Linkage Installation . . . . . . . . . . . . . . . . . . . . . .40
7-6 Control Lever/Linkage Adjustment . . . . . . . . . . . . . . . . .41
8-1 Body Assembly/Canopy Attachment . . . . . . . . . . . . . . . .42
8-2 Body Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Decal Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8-3 Main Rotor Blade Assembly . . . . . . . . . . . . . . . . . . . . . . .44
8-4 Main Rotor Blade Final Balancing . . . . . . . . . . . . . . . . . .45
8-5 Main Rotor Blade Final Attachment . . . . . . . . . . . . . . . . .45
Final Servo Adjustment and Radio Set Up . . . . . . . . . . . . . . . . . .46-47
Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48-51
Final Pre-Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Range Test/Initial Engine Start-Up & Adjustment . . . . . . . . . . . .53-54
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Rotor Head/Swashplate/Washout Assembly Parts List . . . . . . . . .56-57
Cyclic Mixing Arms/Elevator/Aileron Control Arms Parts List . .58-59
Start Shaft/Clutch/Engine Assembly Parts List . . . . . . . . . . . . . . .60-61
Upper Main Frame/Radio Tray/Body Set Parts List . . . . . . . . . . .62-63
Lower Main Frame/Landing Gear/Fuel Tank Parts List . . . . . . . .64-65
Tail Boom/Tail Brace/Tail Boom Carrier Parts List . . . . . . . . . . .66-67
Tail Case/Tail Blade Holders/Tail Pitch Plate Parts List . . . . . . . .68-69
Zenoah G23 Engine Service/Information Parts . . . . . . . . . . . . . . . . .70
INDEX
Section Description Page Section Description Page

ITEMS REQUIRED TO COMPLETE THE JR ERGO
1. RADIO SYSTEM REQUIREMENTS (NOT INCLUDED):
6-channel or greater PCM R/C helicopter system with 5 servos, 1000 mAh receiver battery and gyro.
(not supplied in kit)
ERGO Z230 FEATURES
Heavy-Duty Aluminum Quad Frame System
Provides excellent rigidity and vibration absorption.
Powerful Zenoah G23 Gas Engine w/Recoil Start
Provides reliable, economical gasoline operation. Convienent
recoil starter included.
Wide Spread Tail Output Shaft Bearings
Reduces vibration and improves control response.
Belt-Driven Tail Rotor Design
Provides easy adjustment and low maintenance. Also eliminates
the need for optional/expensive tube drive shafts.
Precision Ball Bearings atAll Critical Locations
Provide low wear, high precision and reduced maintenance.
Unique Cyclic Mixing Control System
Offers easy adjustment and precise control.
Self-Aligning One-Piece Steel Clutch System
Offers easy installation and adjustment with exceptional reliability.
Straight Blade Axle Rotor Head Design
Provides high responsiveness and solid blade tracking.
Low Drag Flybar Paddles
Provide quick yet smooth cyclic response at all flight speeds.
Heavy-Duty Main Blade Grips with 4mm Blade Bolts
Provide a solid and secure mounting surface to easily handle
the stresses of radical flight.
Heavy-Duty Tail Boom Carrier
Provides increased structural rigidity and improved tail rotor precision.
Superior Parts Fit and Finish
Make assembly trouble free and enjoyable.
4
JRXP783 PCM JRXP8103 PCM JRPCM10SX PCM
Flight Pack Gyro PCM Receiver
Note: Due to the additional RF interference generated by the Zenoah G23 gasoline
engine, it is highly recommended that only a PCM (Pulse Code Modulation)
system be used with the Ergo Z230.

5
Double Sided Servo
Mounting Tape Dubro Brass Sintered Fuel Filters (2pc)
(DUB161)
Nylon Wire Ties (to secure
radio wires, etc) 5 Minute Epoxy or Rotor Blade
CA Adhesive
Gasoline Fuel Tubing
(AER1073) Whip Antenna
(RVO1010)
Gasoline Fuel Filter
(DUB341)
Locktite 242 (Blue)
Locktite (Red)
2. BUILDING SUPPLIES (NOT INCLUDED):
The following items are needed to complete the assembly of the JR Ergo Z230:

6
Needle Nose Pliers
Drill and Drill Bits
Allen Wrenches: 1.5, 2.0, 2.5, 3.0, 4.0mm
Sandpaper (80-100 Grit) Blade Balancer Adjustable Pliers
Small Hammer Hobby Knife Metric Ruler
Scissors
DOT Approved Gasoline Can
(93 octane unleaded gasoline
recommended w/2 cycle oil added)
Pitch Gauge
Gasoline Fuel Pump 2 Cycle Oil Additive
(21 to 25% mix ratios) Fire Extinguisher
Ball Link Pliers Training Gear (Beginners Only)
Phillips Screwdriver Nut Drivers: 5mm, 7mm
3. TOOLS NEEDED TO ASSEMBLE THE JR ERGO Z230 (NOT INCLUDED):
4. FIELD EQUIPMENT REQUIRED (NOT INCLUDED):

7
Socket Head Bolt Self Tapping Screw Flat Washer
.05mm
Flat Head Screw Lock Nut
There are a variety of sizes and shapes of hardware included in this kit.
Prior to assembly, please be careful to identify each screw by matching it to the
full size screw outlines included in each step.
All of the hardware, screws, nuts, etc., contained in the Ergo kit are described in
the following A, B, C manner:
CC
C
A
A
B
A
A
B
B
BC
AB
3x8mm Socket Head Bolt
Set Screw
C
A
B
C
C
A
A
A
A
B
2x8mm Flat Head Screw
2.6x10mm Self Tapping Screw AB
B
3mm Flat Washer
AB
B
3mm Lock Nut
Star Washer
AB
B
3mm Star Washer
A
B
Flat Head Cap Screw
AC
B
C
3x8mm Flat Head Cap Screw
A
Hex Nut
AB
B
2mm Hex Nut
C
AB
4x4mm Set Screw
HARDWARE IDENTIFICATION

8
1-1
4x4mm Set Screw
Use Threadlock
..........1 pc
3x6mm Socket Head Bolt
...1 pc
3mm Flat Washer
.........1 pc
CLUTCH BELL/START SHAFT ASSEMBLY
1-2 TAIL DRIVE PINION/BEARING BLOCK ASSEMBLY
Install the Lower Bearing Block so the
bearing face is toward the top
Install the Upper Bearing Block so the
bearing is toward the bottom
Tail Drive Pinion
Bearing Blocks
Tail Drive Pinion
with Shaft
Front Tail Belt Pulley
(Install Flat Side Up)
3mm Flat Washer
3x6mm Socket Head Bolt (Use Red Threadlock)
Complete Assembly
4x4mm Set Screw (Use Threadlock)
Starter Hex Adaptor
Start Shaft Bearing Block
Note: These items are
pre-assembled
Start Shaft
Clutch Bell Assembly
Be sure that the Bearing with
the 5mm ID faces upward
Pinion Gear (13T)
(Use Threadlock when
assembling)
Complete Assembly
Note: It will be necessary to
press the two Bearings
into the Bearing Blocks.
Press the Bearings in
evenly by hand. Do not
use a vise or pliers for
this procedure as
damage could result.
Use Red Threadlock
RED
RED
UP
UP
Bearing
Bearing
Z,Q
Z,Q
*
*

1-3 CONTROL BALL INSTALLATION
1-4 SERVO MIXING LEVER UNIT ASSEMBLY
........1 pc
........8 pc
........9 pc
2mm Nut ........3 pc
3x8mm Flat Head Screw
3mm Lock Nut
........2 pc
....1 pc
........1 pc
3x55mm Socket Head Bolt
....4 pc
2mm Nut
3x5x1.8mm Spacer
Steel Joint Ball
5x8x4mm Ball Bearing
2x10mm Flat Head Screw
2x10mm Flat
Head Screw
3x5x3.8mm Spacer
Mixing Lever (3pc)
(Prepare 3 Sets)
5x8x4mm Ball Bearing
2mm Nut
2x8mm Flat Head Screw
(Use Threadlock)
Steel Joint Ball
3x4.5x.7mm Steel Washer
........1 pc
3x55mm Socket
Head Bolt
3x8mm (x2)
Flat Head Screw
(Use Threadlock)
Mixing Base Arm (Roll)
Mixing Lever Spacer
Mixing Base Cross Member
3x4.5x.7mm (x4)
Steel Washer
Complete Assembly
3mm Lock Nut
Mixing Base Cross Member
9
Use Threadlock
Use Threadlock
........8pc
Z,Q
Z,Q
........3pc
.......1pc
3x5x1.8mm Spacer
5x8x4mm Ball Bearing
2x10mm Flat Head Screw
2x8mm Flat Head Screw
3x5x3.8mm Spacer
Steel Joint Ball
........5 pc
Mixing Lever Spacer

1-5 ELEVATOR ARM ASSEMBLY
10
2x8mm Flat Head Screw
.........2 pc
Elevator Arm Pin .......2 pc
..........2 pc
2x8mm Flat Head Screw
Steel Joint Ball
Elevator Arm Front
Elevator Arm Pins
Steel Joint Ball
Swashplate A Arm
Swashplate A
Arms
Edge of Work Bench
Elevator Arm
Tap in gently with
a small hammer.
Elevator Arm Rear
2x8mm Flat
Head Screw
Caution: Be sure to note the correct installation direction of the Swashplate A Arm.
Elevator Arm (Front) Elevator Arm (Rear)
Marked Side Out
Swashplate A
Arm Swashplate A
Arm
Marked Side In
Z,Q
Steel Joint Ball

1-6 FUEL TANK ASSEMBLY
11
1. Cut the small Gasoline Tubing
(included) to a length of 77mm. Next,
connect the Fuel Tank Clunk, Nipple, and
medium Gasoline Fuel Tubing (not
included) as shown below.
2. Insert the assembly above (Fuel Tank
Clunk first) into the Fuel Tank opening so
that the Nipple is inside the tank. Next,
slide the Fuel tank Grommet over the
medium Fuel Tubing.
3. Insert the Fuel Tank Grommet into the
Fuel Tank opening, making sure that it is
fully seated. Make sure Grommet is
fully seated. 6. Completed Assembly
4. Pull the medium Gasoline Fuel Tubing
out of the Fuel Tank until the threads of
the Fuel Tank Nipple are exposed.
5. Remove the medium Gasoline Fuel Tubing
from the Nipple and secure the Nipple to
the Fuel Tank using the 7x12x1mm Washer
and 7mm Nut supplied. Be sure to
secure this assembly firmly to avoid leakage.
Gasoline Fuel Tubing (not included)
Connects to Muffler Pressure Tap
Medium Gasoline Fuel Tubing (not included)
Connects to Engine Carburetor
Nipple
Fuel Tank Grommet Pull out until
Nipple threads
are exposed
7x12x1 Washer
7mm Nut
Use two Wrenches
if necessary to
secure Tank Nipple.
Gasoline Fuel
Tubing (Small)
Fuel Tank
Clunk
77mm
Z,Q
Note: The Fuel Tank Fittings included in the Z230
kit are made specifically for gasoline use.

12
Note: Be sure to use the two
shorter Body Mount
Standoff for this installation.
Note: Due to the addition of the
Frame Double Plates, only
four 3mm Flat Washers are
required for this step.
*This hardware is packaged seperately
with the two Frame Doubler Plates.
*
*
*
*
*
*
*
*
*
*
*
*
3x8mm Socket Head Bolt ..........22 pc
Body Mounting Standoff ..........2 pc
3mm Flat Washer ..........11 pc
3x6mm Socket Head Bolt ..........1 pc
2.6x8mm Self Tapping Screw ..........4 pc
3mm Lock Nut ..........2 pc
Tail Control Rod Guide
3x6mm Socket Head Bolt
Body Mounting Standoff: Short
Bearing side must face upward
3mm Flat Washer
(11 pc)
Frame Double Plate
(2pc)
Bearing side must
face downward
*3mm Lock Nut
(2pc)
Servo Mounting Plates
2.6x8mm Self Tapping
Screws
2-1 UPPER MAIN FRAME SECTION ASSEMBLY
Upper Main Shaft Bearing Block
When installing the Main Rotor Shaft Bearing Blocks, it is important to note the correct direction in which they need to be installed.
Please refer to the diagram below for clarification.
Position so the side of
the bearing block that
has the bearing flush
with the flange is upward.
UP
Lower Main Shaft Bearing Block
Position so side of the
bearing block that has the
bearing flush with the
flange is downward.
UP
Bearing Flush
with Flange
Bearing Bearing
Bearing Flush
with Flange
Use Threadlock
3x8mm Socket Head Bolt
(21 pc)
Z,Q

13
2-2 UPPER MAIN FRAME CONTROL LEVER INSTALLATION
Note: Be sure to install the Elevator
Arm Units in their proper
location as there is a “Front”
and a “Rear” Unit (Step 1-5).
Nylon Washer
Elevator Arm Bushing
3x6mm Socket Head Bolt
Elevator Arm Bushing
Nylon Washer
3x8mm Socket Head Bolt
........2 pc
........4 pc
........1 pc
Nylon Washers ........4 pc
......1 pc
3x22mm Socket Head Bolt
Elevator Arm Bushing ........2 pc
Mixing Base Nut ........2 pc
........1 pc
Mixing Base Nut (2 pc)
3mm Flat Washer
3x6mm Socket Head Bolt
Roll Bell Crank Spacer ........1 pc
3mm Lock Nut
Use Threadlock
3x8mm Socket
Head Bolt
Z,Q
Nylon Washer 3mm Lock Nut
Roll Bell
Crank Spacer 3x22mm Socket Head Bolt
3x6mm Socket
Head Bolt
(Use Threadlock)
3x4.5x.4mm
Steel Washer Roll Bell
Crank
B
C
Adjustment Length
Rod Length
Assemble and attach the Control Rods to the
Mixing Levers/Control Arms as shown:
Note: When adjusting final control rod
lengths, make sure that “JR Propo”
moulded into the Ball Link faces outwards
before attaching to the Steel Joint Balls.
A
Rod Length Adjust Length To
120mm 104mm
55mm 36mm
90mm 72mm
A
B
C
3x8mm Socket
Head Bolt
(Use Threadlock)

2-4 FUEL TANK INSTALLATION
Assembled
Fuel Tank
3x8mm Socket Head Bolt (2pc)
Tank Mounting Rubber
Attach a small piece of
double sided 1/8" servo tape
(not included) to the inside of
the two tank holders prior to
installation.
Note: Select the correct Tank
Mounting Rubber as follows:
Ergo Z230: Grey (Soft)
Ergo Quattro: Black (Hard)
Note: Install the Fuel Tank and Tank Mounting
Rubber into the lower frame halves before
attaching the Main Frame Standoffs.
When securing Standoffs to Frame, position
the bottom of the frame on a level surface to
prevent twisting during tightening.
Also be sure to use the correct length bolt in
the correct location when assembling.
Main Frame Standoff (2pc)
3x10mm Socket Head Bolt (4pc)
Fuel Tank Holder
(2pc)
3mm Lock
Nut (2pc)
14
......2 pc
3x8mm Socket Head Bolt
......2 pc
3mm Lock Nut
Main Frame Standoff, 80mm
2-3 LOWER MAIN FRAME ASSEMBLY
3x10mm Socket Head Bolt
Use Threadlock
Use Threadlock on all
screws in this assembly.
......4 pc
...3 pc
3x8mm Sockethead Bolt (4pc)
ERGO Z230 ONLY
Lower Frame Angle (2pc)
* Note: Make sure that the frames are positioned
so that the counter sunk screw holes face
towards the inside of the Main Frame
Assembly as shown. 4x12mm
Socket Head Bolt
4mm Nut
*Counter Sunk Holes 3x8mm Socket Head Bolt
(Use Threadlock)
3mm Lock Nut (8pc)
3x10mm (4pc)
Flat Head Screw
Lower Main
Frame Halves
......8 pc
2.6x8mm Self Tapping Screw
......4 pc
3x10mm Flat Head Screw
......4 pc
....10 pc
3x8mm Socket Head Bolt
3mm Lock Nut
......1 pc
....1 pc
4x12mm Socket Head Bolt
4mm Lock Nut
Servo Installation Plate
2.6x8mm
Self Tapping Screw
ERGO Z230 ONLY
Z,Q
Z

2-5 FRONT RADIO BED/INSTALLATION
2-6 COOLING FAN SHROUD INSTALLATION
15
*Front Radio Bed Spacers (2pc)
Front Radio Bed
3x25mm Set Screw
(2pc)
Body Mounting
Standoff, 29mm
(2pc)
UP
Shorter
Distance
Front Radio
Bed Spacer 3x18mm Socket Head Bolt
(2pc)
* Install the Front Radio Bed
Spacer in the correct
direction as shown.
Install the 3x25mm Set Screw into
the Body Mounting Standoffs to the
correct distance as shown and
secure with Threadlock.
Cooling Fan Shroud
3x8mm Self Tapping
Screw (4pc)
Remove
Before installation, remove the shaded areas of the
Fan Shroud as shown above. The exact trimming
outlines are moulded into the inside portion of the
cooling fan shroud for convienience.
.....2 pc
3x18mm Socket Head Bolt
.....2 pc
3x25mm Set Screw
Body Mounting Standoff, 29mm .....2 pc
Use Threadlock
Z,Q
......4 pc
3x8mm Self Tapping Screw
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2-7 UPPER/LOWER MAIN FRAME ASSEMBLY ATTACHMENT
16
......14 pc
3x22mm Socket Head Bolt
Main Frame Standoff, 32mm
......14 pc
Main Frame Spacer, 22mm
Use Threadlock on all
screws in this assembly.
.....7 pc
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Main Frame Spacer, 22mm
(14pc)
3x22mm Socket Head Bolt
(14pc)
Main Frame Standoff,
32mm (7pc)

3-1 MAIN DRIVE GEAR/AUTOROTATION ASSEMBLY
3-2 MAIN DRIVE GEAR/AUTOROTATION ASSEMBLY INSTALLATION
17
3x6mm Socket Head Bolt (4 pc)
Tighten equally to prevent
warping of Main Drive Gear
Main Drive Gear
Autorotation Assembly
4x4mm Set Screw (4 pc)
Main Shaft Collar
Main Rotor Shaft
14mm
3mm
4x4mm Set Screws (4pc)
1. Secure the Autorotation Hub to the Main Rotor Shaft
using four 4x4mm Set Screws. Next, slide the
Main Shaft Collar onto the Main Rotor Shaft. While
pulling upward on the Main Rotor Shaft, secure the
Main Shaft Collar to the Main Rotor Shaft using the
remaining four 4x4mm Set Screws. 2. Once the Main Shaft Assembly is in place, adjust the gear mesh of the Clutch Bell
and Tail Belt Pinion Gears, and secure the bolts left loose from Step 2-1.
3x6mm Socket Head Bolt
.......4 pc
4x4 Set Screw
.......8 pc
Use Threadlock
Use Threadlock on all
screws in this assembly
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When assembling, be sure that two of
the four 4mm Set Screws engage into
the through hole in the bottom of the
Main Rotor Shaft.

3-3 LANDING GEAR ASSEMBLY INSTALLATION
3-4 ENGINE PREPARATION/COOLING FAN INSTALLATION
18
3x12mm Socket Head Bolt ......4 pc
4x4mm Set Screw ......4 pc
3mm Washer ......4 pc
......4 pc
3x8mm Socket Head Bolt
3x8mm Socket Head Bolt
(4 pc)
4x4mm Set Screws
(4 pc)
3mm Washer (4 pc)
Landing Skid
*Landing Skid Cap
6x18mm Socket Head Bolt ......1 pc
6x18mm Socket Head Bolt
Zenoah G23 Engine
Coil Assembly
Carburator
Insulator Plate
Carburator
Aluminum Cooling
Fan Assembly
Use Threadlock
Use Threadlock
Z,Q
Landing Gear Dampers (4 pc)
* Use CA Adhesive to attach
Landing Skid Caps to Skid Tubes
3x12mm Socket
Head Bolt (4 pc)
At this time, please remove the Aircleaner
Assembly, Carburator, Carburator Insulator
Plate, and Coil Assembly as shown below:
Z
Air Cleaner
Assembly

3-5 CLUTCH ASSEMBLY ATTACHMENT
19
Clutch Assembly
4x6mm
Socket Head Bolt (2pc)
Apply a light coating of oil or grease
to the bearing before installation.
4x6mm Socket Head Bolt
......2pc
3x15mm Socket Head Bolt ......4pc
3mm Lock Nut ......4pc
4mm Lock Nut ......2pc
3mm Washer ......4pc
4mm Washer ......2pc
Coil Grounding Wire ......2pc
3x8mm Socket Head Bolt ......1pc
4x8x14mm Coil Mounting Spacers
......2pc
4x30mm Socket Head Bolt ......2pc
Use Threadlock
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3-6 ENGINE INSTALLATION
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INCORRECT INCORRECT CORRECT
Adjust the position of the Engine and Clutch Assembly
as shown so the bottom of the Clutch Assembly is flush
with the bottom of the Clutch Bell. Also check to insure
that the Engine and Clutch Bell are parallel.
3mm Lock Nut
(4pc)
4mm Lock Nut
(2pc)
Make sure that the Coil Sheild
Grounding Wire makes contact
with the exposed brass plate
moulded into the Coil Mounting Tab.
4x30mm Socket
Head Bolt
3mm Washer
(4pc)
Red Coil Wire
(Connect to Red Coil
Wire from engine
after installation)
Red Coil Wire
(Connect to Red Wire from
Coil after engine is installed)
Black Coil
Wire
(Ignition kill
not required)
Coil
Assembly
Coil
Grounding
Wire
4mm Washer
(2pc)
Coil Shield
Coil Mounting
Spacers
3x15mm Socket
Head Bolt (4pc)

3-7 MUFFLER INSTALLATION
20
Dubro Sintered
Bronze Filter (2pc)
(not included)
Note: It is suggested that an In
Line Fuel Filler be installed into the
Main Fuel Line (not included).
Fuel Line (6" Long)
Connect to Fuel Inlet
Nipple as shown.
Carburator
Overflow Vent
(9" Long)
Carburator
Assembly
Air Filter
Air Cleaner Cover
5x55mm Air Cleaner
Mounting Bolts (2pc) Air Cleaner
Body
Steel Joint Ball
3x3mm
Set Screw
* Throttle Arm 2mm Nut
2x8mm Flat Head Screw
Nylon Wire Tie (2pc)
(not included)
* Carburator
Overflow Vent: Duplicate on other side of
Heli for Fuel Tank Vent
Carburator
Gasket
Attach the Carburator Overflow Vent Line and
the Fuel Tank Vent Line to each side of the
Mainframe as shown at right. Make sure that
the Sintered Filters are below the frame.
Fuel Tank
Vent
(7" Long)
......1pc
4mm Lock Nut
.....4 pc
4mm Washer
...2 pc
4x12mm Socket Head Bolt
.....2pc
5x55mm Air Cleaner Mounting Bolts
.....1pc
2x8mm Flat Head Screw
.....1pc
2mm Nut
.....1pc
Steel Joint Ball .....1pc
3x3mm Set Screw
.....2pc
5x20mm Carburator Insulator Plate Bolt
Use Threadlock
Use Threadlock
Z
4x12mm Socket Head Bolt
(Installed in Step 2-3)
Secure the Muffler Tab to the 4x12mm
Socket Head Bolt as shown below.
Muffler
Muffler 5x60mm Socket
Head Bolt (2pc)
Muffler Spacer
Muffler Gasket (2pc)
4x12mm Socket Head Bolt
4mm Washer (2pc)
Muffler Tab
4mm Lock Nut
5x20mm Carburator
Insulator Plate Bolt (2pc)
Carburator
Insulator Plate
Insulator Plate Gasket
3-8 CARBURATOR/AIR CLEANER ASSEMBLY INSTALLATION
Z
Included
with
Engine
5x60mm Socket Head Bolt .....2pc
4mm Washer (2pc)
*Install the
Throttle Arm so
that when the
Carburator is at
1/2 throttle, the
Throttle Arm is
exactly 90° to
the Carburator
Flange as shown
above use
Threadlock