Warning. Repair of the steering gear is allowed only in exceptional cases. As a general rule, a defective steering gear should be replaced.
Remove the tie rods and rack as above.
Remove the cover, remove the safety cotter pin and unscrew the rail stop adjusting screw.
Remove the collar and rack stop spring.
Remove the boot and circlip of the drive gear, and then the toothed ring.
Unscrew the adjusting nut of the drive gear with the key 32 1 040.
Remove the O-ring and mounting washer.
Clamp the splined end of the drive gear in a soft grip vise.
Knock the drive gear out of the steering gear housing by lightly tapping it with a plastic-headed hammer.
Install the retaining ring on the drive gear and press the ball bearing off the gear using a press.
Press the needle bearing out of the steering gear housing using a puller (e.g. Kukko 00 8 510).
Using two screwdrivers, remove the protrusions of the sleeve from the retainers and remove the liners from the crankcase.
Assembly
Insert new O-rings into the bushing and install the bushing into the steering gear housing.
Press the needle bearing into the crankcase seat with the rounded end of the mandrel.
Press the ball bearing onto the drive gear using a press with the bearing cap facing towards the gear splines.
Having generously lubricated the teeth of the rack with grease, and its other surfaces with a thin layer of the same grease, install the rack in the crankcase.
Install the drive gear into the crankcase, after applying grease to its teeth.
Install the plastic washer and O-ring onto the gear shaft.
Tighten the adjusting nut of the drive gear to 22-27 Nm using a special wrench 32 1 040
Install the retaining ring into the groove of the gear shaft and press the toothed ring onto it until it stops.
Set the rack to the midpoint position, maintaining a dimension of 77 mm between the ends of the rack and the steering gear housing tube from the side of the rack support sleeve.
Place the boot on the drive gear so that the mark on the boot is between the marks on the steering gear housing.
Install the O-ring on the rack stop and insert the rack stop into the steering gear housing.
Replace the spring and the cuff of the rack stop.
Tighten the adjusting screw of the rack stop until it stops, then unscrew it by 12 mm.
Adjust the rack stop and check the torque of the drive gear.
In the future, the assembly and installation of the steering mechanism is carried out in the reverse order of disassembly and removal (see relevant subsections).