Section of the crankcase of the steering mechanism
1 - plate of the adjusting screw of the bipod shaft; 2 - adjusting screw of the bipod shaft; 3 - adjusting screw nut; 4 - oil filler plug; 5 – a cover of a case of the steering mechanism; 6 - worm; 7 - crankcase of the steering mechanism; 8 - bipod; 9 - nut for fastening the bipod to the shaft; 10 - spring washer of the bipod fastening nut; 11 - bipod shaft cuff; 12 - bronze bushing of the bipod shaft; 13 - bipod shaft; 14 - bipod shaft roller; 15 - worm shaft; 16 - upper ball bearing; 17 - lower ball bearing; 18 - adjusting shims; 19 - the lower cover of the worm bearing; 20 - roller axis; 21 - needle bearing; 22 - cuff of the worm shaft.
Drain the oil from the gearbox housing, unscrew the adjusting nut and remove the lock washer.
key «on 10» unscrew the four bolts securing the upper cover of the gearbox.
We remove the head of the adjusting screw from the groove on the bipod shaft and remove the cover.
When replacing the bipod shaft, the axial clearance between the screw head and the shaft groove is eliminated by selecting the thickness of the adjusting plate. The gap size is allowed no more than 0.05 mm. The plates have a thickness of 1.95 to 2.20 mm in increments of 0.025 mm.
We take out the bipod shaft with the roller from the crankcase.
key «on 10» unscrew the four bolts securing the worm shaft cover and...
... remove it together with the ball bearing adjustment shims.
Gaskets are available in thicknesses of 0.1 and 0.15 mm.
With light blows of a soft metal hammer, we knock out the worm shaft from the gearbox housing together with the bearing.
On the end surfaces of the worm, running tracks for bearing balls are made.
Prying with a screwdriver, take out the cuff of the worm shaft.
Similarly, we take out the cuff of the bipod shaft.
We knock out the outer ring of the second bearing with a beard.
We wash all parts in kerosene or diesel fuel. We carefully check the absence of signs of wear, scoring or damage on the working surfaces of the roller and worm. The gap between the bipod shaft and bronze bushings should not exceed 0.1 mm. Ball bearings must rotate freely, without sticking, on the surfaces of rings, cages and balls there must be no damage or wear. Cracks of any length are not allowed on the crankcase itself. We replace worn and damaged parts with serviceable ones. We replace the cuffs with new ones in any case. Before assembly, lubricate all internal parts with gear oil.
With light hammer blows on a piece of pipe of a suitable diameter, we press the inner bearing ring into the crankcase.
It is possible to press in the bearing ring using the tool for replacing rubber-metal joints of the front suspension (see Applications).
We install a separator with balls in the bearing ring and insert the worm shaft. We put the outer bearing separator on it and press the outer ring with light blows of the hammer. Put on the lid and...
... we press in the cuffs of the worm shaft and bipod, lubricating the working edges with Litol-24 grease.
We install a worm in the crankcase. With a set of shims, we set the moment of its rotation from 2 to 5 kgf cm. We install the bipod shaft and adjust the gap in engagement according to the moment of turning the shaft. It should be 7–9 kgf cm when the worm shaft is turned 30°to the left and right, and gradually decrease to 5 kgf cm with further rotation to the stop.
Pour gear oil into the crankcase to the level of the lower edge of the filler hole (0.215 l).
Dimensions of the main mating parts and limits of permissible wear
Mating Parts | Dimensions of mating parts, mm | Permissible gap in mating, mm | |||||||
Hole | Shaft | ||||||||
Pivot Shaft Bushing - Pivot Shaft | 28,698+0,022 | 28,690-0,021 | 0,1 | ||||||
Steering gear housing - upper worm bearing |
| 47-0,011 | Free running is not allowed | ||||||
Steering gear housing - lower worm bearing | 500,025 | 50-0,011 | 0,06 | ||||||
Swingarm Bracket - Swingarm Shaft Bushing |
|
| 0,175 | ||||||
Pendulum axle bush - pendulum axle |
| 20-0,050 | 0,3–0,5 |