Service Manual
Page 48 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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Assemble the mainshaft selector fork onto the longer selector rail with the selector pin towards the shouldered end. Fit the rail into the crankcase so that the fork engages the groove in 4th gear. Do not push the selector rail fully home at this stage.
Fit the shim-washer to the selector drum with the inner chamfer against the shoulder of the drum. Position the selector drum in the crankcase bore, ensuring that the pins of the selectors engage in the grooves of the drum. It may be necessary to manoeuvre the gears along their shafts a little to allow both selector rails to be pushed fully home. At this stage check that when the selector drum is turned all three forks move to and fro. To do this, turn the mainshaft with one hand to allow the dogs to move in relation with each other while turning the selector drum with the other hand. It is not necessary to leave the selector drum in any particular position.
Assemble onto the idler shaft in the crankcase the following parts: Thrust washer A Idler gear B 25 teeth, longer shoulder facing right Needle bearing C Thrust washer D Note that the grooved faces of the thrust washers face towards the gear.
Fit onto the final drive shaft assembly the shimwasher, with the inner chamfer to the gear face. Fit the spacer onto the splined end of the shaft, with the chamfer over the shoulder. This spacer fits over a bearing ring which is a press fit onto the shaft, and need not normally be removed.

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