Kawasaki Ninja GPX600 engine repair at home. New gears improved gearbox and starter clutch rebuild.

More pictures about the engine repair of the Kawasaki Ninja GPX 600 Digital Edition. The main failures were the starter clutch BENDIX and the gears of the transmission. Fortunately I was able to find the gearbox parts from a non working broke engine from year 1991 replacing all the gears. It was a work of three months the overhaul improvements of the gearbox and overall repair of the GPX 600. The most difficult part was the soldering of the broken gear shaft on the aluminum engine block with an electric inverter welder. Because of he welder arcing protection without settings for aluminum sticks it was very choppy unstable the current with interruptions being impossible to achieve a continuous melting flow. With patience the broken aluminum shaft was fixed being now the axle bushing shorter. With such changes is much better with a very soft actuation on gears engage comparing the factory foot shaft design with a large aluminum bushing design. I also improved the gearbox internal drum shift selector increasing the axial gears displacements for an accurate engage on all speeds from 1st to 6th. The water pump flow on the inlet port has now a bigger diameter because the OEM design was to small affecting the cooling efficiency. All radiator hoses were reinforced with zip straps to avoid failures. The motorcycle use a 90 tubes triple pass water flow radiator made at home because the OEM with only 36 tubes was very inefficient to cool down the engine at safe temps. The clutch OEM plates are in very good condition only 30% wear with 120 thousand km of usage. On the assembling softer clutch springs are installed being now the clutch hand control very precise. Engine crankshaft, cylinders, pistons and connecting rods bearings are in very good condition without oil consumption on the exhaust after 120.000 km of usage. The camshaft timing chain and crankshaft primary chain are at 50% of wear meaning that is possible to achieve 200 thousand kilometers of usage before replacement of the parts. The motorcycle use now a digital igniter unit TCI box with precise spark timing advance and over RPM cutoff.