Service Manual
Page 10 of 50

*NOTE* This service manual is for a NON EN10 modified engine. Whilst most of the information is relevent, there are some critical differences.
For more information on EN10 modified engines, please contact
Mick Broom at Broom Development Engineering on +44 (0)1327 353023

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Refit the neutral indexing plate, plain washer and socket screw (6mm Allen key). Loctite screw-lock should be used on the socket screw. When tightening the socket screw, turn the selector barrel shaft to the bottom position (clockwise so that the neutral notch is uppermost), to avoid stress on the selector forks. Fit the small spacer and the circlip retaining the star wheel to the selector rail shaft. Ensure that the circlip is locked correctly in the groove of the shaft. NOTE:- Before continuing to assemble, check that the whole mechanism is free to turn. (minimum end float 0.05mm ).
Place the neutral plunger and spring into its bracket and offer up the complete assembly to its location, threading the neutral wire through the hole in the crankcase. This is most easily done with the plunger engaging the neutral notch of the indexing plate. The three retaining socket screws (5 mm Allen key) and the roller arm pivot pin (10mm spanner) should be fitted using Loctite screw-lock. When this plate is in position, check with a circuit tester that the neutral light operates correctly. Continuity between the wire and the crankcase should only exist when neutral plunger is in its notch.
Refit the quadrant assembly onto the gear crossover shaft with the plain washer and self locking nut (13mm spanner). NOTE:- Adjustment of the eccentric should be left until the roller arm has been fitted.
Fit the roller arm with its spring and locate it with the E clip, noting that the sharp edge of the E clip should face outwards.

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