Synergy 766 User manual

ASSEMBLY MANUAL AND PART REFERENCE
WWW.SYNERGYRCHELICOPTERS.COM
MANUAL VERSION 5.1.14

WWW.SYNERGYRCHELICOPTERS.COM 2
Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
INTRODUCTION
Congratulations on your purchase of the Synergy 766 model helicopter kit!
The Synergy 766 was designed and developed by Matt Botos, a world class competition model helicopter pilot, and is the result of thousands of
hours of research and experience.
Before you proceed please verify you have the latest version of this manual by visiting our website at http://synergyrchelicopters.com/manuals.
If you have any questions during the assembly process or need clarication on anything in this manual please visit our forums at
http://synergyrchelicopters.com/forum where you will nd great tips and expert advice.
THIS RADIO CONTROLLED HELICOPTER IS NOT A TOY. IT IS A SOPHISTICATED PIECE OF EQUIPMENT DESIGNED AND INTENDED FOR
RECREATIONAL USE ONLY. IF NOT PROPERLY ASSEMBLED, MAINTAINED, AND OPERATED, IT IS CAPABLE OF CAUSING PROPERTY
DAMAGE AND BODILY HARM TO BOTH THE OPERATOR AND SPECTATORS. BOTOS DESIGN & DISTRIBUTION, ITS AFFILIATES, AND ITS
AUTHORIZED DISTRIBUTORS ASSUME NO LIABILITY FOR DAMAGE THAT COULD OCCUR FROM THE ASSEMBLY OR USE OR MISUSE OF
THIS PRODUCT. USE THIS PRODUCT AT YOUR OWN RISK.
Operating a model helicopter requires a high degree of aptitude and meticulousness. If you are new to model helicopters, it is your responsibility
to seek help and guidance from experienced modelers. Having an experienced modeler inspect your model and provide instruction will both
greatly speed up the learning process and make it much safer for you. For those pilots who will be operating their Synergy 766 in the United
States, we strongly recommend joining the AMA. The AMA is a non-prot organization that provides services to the model aircraft pilots. As an
AMA member, you will receive a liability insurance plan to cover against a possible accident or injury. All AMA charter clubs require individuals to
hold a current AMA membership prior to operation of their models at their facility.
For further information, you can contact the AMA at:
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302
[phone]
https://www.modelaircraft.org
INTRODUCTION

WWW.SYNERGYRCHELICOPTERS.COM 3
Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
SPECIFICATIONS
SPECIFICATIONS AND FEATURES
• Main Blades: 716-806mm
• Available Main Gear Ratio: 9.27-11.58*
• Available Tail Gear Ratios: 4.5 / 4.7 / 5.1*
• Available Boom Sizes: 716 / 766 / 806*
• Tail blades: 106-116mm
• Battery Conguration: 12s-14s
• 64mm frame width
*This kit includes the following:
• 13T main pinion
• 4.7 tail ratio (27T Pinion). See page 8.
• Boom, torque tube, and tail control rod lengths optimized for
766mm main blades. See pages 64-67 for specic sizes.
Optional parts are available from the Synergy RC Helicopters
website at http://www.mattbotos.com/store.
Main and tail blades are not included.
SPECIFICATIONS: MAIN FEATURES:
• CNC Machined Helical mod 1 main and auto gears
• Monster-mod 1.25 24T front and rear tail drive bevel gears
• Torque tube tail drive for high efciency
• Ultra-wide head for rigid, precise control
• Tunable blade grip pitch arm geometry
• 12mm Main Shaft / 10mm Spindle & rocker support
• Dual main shaft thrust bearings
• Serviceable dual-bearing swash plate system
• Quad progressive & adjustable head dampening
• Turnbuckle linkage adjustments
• Low disk loading
• Multiple tail drive ratios
• Locking battery tray with CG adjustment
• Optimized tail arm geometry
• Optimum boom options for each blade size
• 3 panel canopy system with high-visibility paint
• Grease ports for all 6 thrust bearings
• CNC Machined Delrin gears
• Designed and supported in the U.S.A

ORIENTATION
!
766-107 Panel Standoff Short
100-306 M3x6 Socket Head
(Medium Viscosity)
(Medium Viscosity)
(Medium Viscosity)
(Medium Viscosity)
100-372 M3x12 Set Screw
100-306 M3x6 Socket Head
766-108 Panel Standoff Long
305-121 Key Chain Canopy Mount 21mm
305-106 Break Away Plate
101-306 M3x6 Button Head
766-103 Main Frame
766-104 Frame Spacer Standard
766-106 Battery Tray Rail
100-351 M3 Nylock Nut
100-308 M3x8 Socket Head
101-306 M3x6 Button Head
DO NOT OVER TIGHTEN!
Bolts threaded into the Delrin Battery Tray Rail require
very little holding torque. Do not over tighten or you
will strip the threads.
!
DO NOT TIGHTEN BOLTS YET
Frame alignment should be verified once both sides are
completely assembled and the main shaft inserted. Unless noted
otherwise, do not fully tighten these bolts yet.
!
WWW.SYNERGYRCHELICOPTERS.COM 4
Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
FRAME SIDE 1
SIDE 1
MAIN FRAME

WWW.SYNERGYRCHELICOPTERS.COM 5
Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
FRAME SIDE 1
MAIN FRAME
SIDE 1

101-306 M3x6 Button Head (4)
310-105 CF Lower Frame Brace
766-110 Gyro Plate
766-109 Boom Support Block 766-105 Frame Spacer Large
103-256 M2.5x6 Type I Cross Recessed (4)
TIGHTEN THESE 4 SCREWS
!
Apply BLUE thread lock to these four (4) screws
and tighten fully.
DO NOT TIGHTEN BOLTS YET
Frame alignment should be verified once both sides are
completely assembled and the main shaft inserted. Unless noted
otherwise, do not fully tighten these bolts yet.
!
WWW.SYNERGYRCHELICOPTERS.COM 6
Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
FRAME SIDE 1
MAIN FRAME
SIDE 1

100-306 M3x6 Socket Head (4)
100-408 M4x8 Socket Head
DO NOT TIGHTEN BOLTS YET
Frame alignment should be verified once both sides are
completely assembled and the main shaft inserted. Unless noted
otherwise, do not fully tighten these bolts yet.
!
!APPLY BLUE THREAD LOCK
TO INDICATED BOLTS
WWW.SYNERGYRCHELICOPTERS.COM 7
Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
FRAME SIDE 1
MAIN FRAME
SIDE 1

100-366 M3x6 Set Screw
766-509 6mm Pinion Shaft
766-601 24T Bevel Gear
320-412 17mm Bevel Gear Pin
**Optional 766-625H 25T Helical Pinion
766-627H 27T Helical Pinion
Included with kit
**Optional 766-628H 28T Helical Pinion
FOR OPTIONAL TAIL DRIVE GEAR
SELECTION SEE PAGE 89
WWW.SYNERGYRCHELICOPTERS.COM 8
Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
TRANSMISSION
TRANSMISSION
TRANSFER SHAFT
IMPORTANT
Tighten and secure set screw with blue
thread lock. This set screw secures the
bevel gear pin!
Prior to assembly, thread set screw the
entire length of the hole to check for
burrs or other obstacles.
!
TAIL DRIVE GEAR INSTALLATION
GREEN thread lock secures the pin, gear, and shaft. RED can be used as an alternative
retainer. Wipe away excess. Removal may require heat.
**Allow Thread lock to dry prior to installation on the following page. Failure to do so
may allow thread lock to wick into the bearings.

108-124 12x18x4 Radial Bearing
766-602 24T Mushroom Gear
100-310 M3x10 Socket Head (2)
766-508 Gear Shaft Bearing Block
766-508 Gear Shaft Bearing Block
100-310 M3x10 Socket Head (2)
108-613 6x13x5 Radial Bearing
108-613 6x13x5 Radial Bearing
FRONT MUSHROOM BEARING BLOCK ASSEMBLY
766-507 Front Mushroom Gear Bearing Block
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Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
TRANSMISSION
TRANSMISSION
BEVEL GEAR BLOCKS
PREASSEMBLED COMPONENTS
The 766-301 24T Front Trans Mushroom Gear Block contains radial
bearings and mushroom bevel gear which does not require disassembly.
**Tip: If repair or disassembly are required, freeze components to easily
remove mushroom gear.**

100-372 M3x12 Set Screw (x8)
100-306 M3x6 Socket Head (x2)
100-306 M3x6 Socket Head (x2)
766-511 TranSupport Standoff (x8)
766-510 TranSupport CF Plate
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Components that are factory assembled
provide a reference for model assembly.
Disassembly and application of thread
lock is required where indicated.
!
FRAME SIDE 1
FRAME SIDE 2
LANDING GEAR
SPECIFICATIONS
TRANSMISSION
MAIN BEARING BLOCKS
BATTERY TRAY
TORQUE TUBE / BOOM / CONTROL ROD
MAIN AND TAIL BLADES
PANEL SYSTEM
OPTIONS AND CONFIGURATIONS
MAIN DRIVE
SWASH PLATE
SWASH PLATE LINKAGES
MOTOR
HEAD ASSEMBLY
PITCH LINKAGES
SERVO INSTALLATION
TAIL AND HUB
INTRODUCTION
TRANSMISSION
TRANSMISSION
SIDE PLATES
!APPLY BLUE THREAD LOCK TO INDICATED
BOLTS AND SET SCREWS