Hi
Hope you have managed to reach the forum OK.
But I did put quite a lot of data on BURMAN on a topic called I think "
Burman 4th Gear selector meltdown"
Click here for the link (
Moderator) because several of us got together on the forum who had had the selector problem and did quite a detailed analysis of the mechanical tolerances in the box.
I did not have the problem, but we did come up with some solutions to make the top gear dogs engage by a greater amount to relieve the stresses on the selector fork and I incorporated the mods. to my box when I rebuilt it to stop grease leaks, in the hope of preventing the selector problem.
All has been fine since and I use Penrite grease with no oil. I thought this grease was thixotropic but it does not seem to be, but can be poured (slowly) or drained if heated up with a heater under the bike.
I have modified the gearchange bearing to incorporate an oilseal and this has worked well for the larger bearing but still leaks a little from the shaft with the indicator.
Matty