Service Manual
Page 9 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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GEAR SELECTOR MECHANISM (REASSEMBLY). Assemble these parts in order to the timing side of the crankcase:
Fit the shim-washer onto the selector barrel shaft; ensure that when this washer is fitted the shoulder of the shaft protrudes slightly through the shimwasher. With a light pull on the shaft a step can be felt between the shimwasher and the shaft shoulder. If in any doubt assemble the whole mechanism and check that a 0.05mm feeler gauge can be inserted between the shim-washer and the crankcase. Replacement shim-washers are available in a range of thicknesses. Refit the feather key, the gear wheel with the chamfer against the shoulder on the selector barrel, and the slotted spacer.
Before fitting the neutral indexing plate, assemble onto the selector rail the large spacer and the star wheel. Do not fit the small spacer and circlip retaining the star wheel until it has been timed correctly, (see below).
Timing the star wheel. In order to check the timing without removing any parts engage bottom gear, (i.e. with the selector barrel shaft turned fully clockwise); the dot on the tooth of the star wheel should lie on a straight line between the two gear centres, as shown, and in line with the centre of the keyway in the selector.

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