Service Manual
Page 46 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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Insert the mainshaft into its bore in the crankcase (needle roller and ball bearing).
Assemble onto the right hand end of the layshaft (longer fine splines) the following parts: Spacer A outer chamfer facing right. 2nd gear B 32 teeth, dogs facing left. Needle bearing C Dog ring D dogs facing right. Splined sleeve E inner chamfer facing right. Bottom gear F 36 teeth, dogs facing left. Thrust washer G inner chamfer facing left. At this stage 2nd gear should rotate but not slide; bottom gear should rotate and slide in and out of engagement with the dog ring.
Assemble onto the central portion of the layshaft the following parts: 3rd gear A 28 teeth, selector groove facing left Spacer B inner chamfer facing right. 4th gear C 25 teeth, dogs facing right. Needle bearing D Top gear E 22 teeth,longer shoulder facing right Shim-washer F inner chamfer facing right.
At this stage check that 4th gear will rotate but not slide, and that 3rd gear will slide but not rotate. Insert the layshaft assembly into its bearing in the crankcase.

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