Warning: Steering gear repair is only permitted in exceptional cases. As a rule, a faulty steering gear must be replaced.
Remove the steering rods and rack as described above.
Remove the cover, take out the safety pin and unscrew the rack stop adjusting screw.
Remove the cuff and the rack stop spring.
Remove the drive pinion dust boot and snap ring, then the toothed ring.
Loosen the drive gear adjusting nut with a 32 1 040 wrench.
Remove the sealing ring and mounting washer.
Clamp the splined end of the drive gear in a vice with soft pads.
Knock the drive pinion out of the steering gear housing by lightly tapping it with a plastic-faced hammer.
Install the retaining ring onto the drive gear and press the ball bearing off the gear using a press.
Press the needle bearing out of the steering gear housing socket using a puller (for example, Kukko 00 8 510).
Using two screwdrivers, remove the bushing protrusions from the retainers and remove the liners from the crankcase.
Assembly
Insert new sealing rings into the bushing and install the bushing into the steering gear housing.
Press the needle bearing into the crankcase seat using the rounded end of the drift.
Press the ball bearing onto the drive gear using a press, with the bearing cap facing the gear splines.
After generously lubricating the rack teeth with consistent grease and its other surfaces with a thin layer of the same grease, install the rack into the crankcase.
Install the drive gear into the crankcase, having first applied consistent grease to its teeth.
Install the plastic washer and sealing ring onto the gear shaft.
Tighten the drive gear adjusting nut to 22-27 Nm using a special key 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 pipe on the side of the rack support sleeve.
Place the boot on the drive pinion so that the mark on the boot is between the marks on the steering gear housing.
Install the sealing ring on the rack stop and insert the rack stop into the steering gear housing.
Replace the spring and the rack stop collar.
Tighten the rack stop adjusting screw until it stops, then turn it out by 12 mm.
Adjust the rack stop and check the drive gear turning moment.
Further assembly and installation of the steering mechanism is carried out in the reverse order of disassembly and removal (see the relevant subsections).