TOPIC:

Thanks Corey,
Yes an '84 with the TK27 carbs. I have new float bowl gaskets (from Kawasaki) but had decided against the K&L kit after reading a lot of bad reviews of them. Have you had a different experience?
I was going to measure the o-rings and replace them all (hopefully from cycle o-rings.com) but stick with stock jetting and airbox for now.
However, after the difficulty getting those carbs off, I am seriously considering velocity stacks just so I can re-jet easily! I will replace the pipes at some point, and that will require a reject.
Does the dyno jet kit for this bike have anything besides jets? That is a lot of money for a few jets.

I have a new fuel sending unit gasket waiting to be installed : )

Also, you have been in these motors a bit.. thoughts on rough area looks going into the cylinder from the carbs?

Thanks,
Lee

Welcome Lee.
Looking forward to your project.

K&L parts are better than nothing if you have no choice, but I'd never choose to run that stuff. The Mikuni float needles have very weak springs which don't hold up the weight of the float for example. Also, often times the jet numbers are off compared to what came in your bike originally. The kits are somewhat generic but Kawasaki often juggled jets from year to year and the kits never account for that.

I have not had any issues with the rebuild kits for the TK27, but things could have changed since I last ran them 4 years ago. Members here have more years with K&L Kits than I do. The bowl gaskets should be formed, and more of the square o-ring type rather than the round for your carbs.

On the o-rings, make sure to replace the one sealing the mixture screws.

The Dynojet Kits come with adjustable slide needles and clips, 4 sets of main jets(2 sets for Stage 1 and 2 sets for Stage 3), and the drills to enlarge the offset hole on the vacuum slides.

Here is a Stage 3 Jet Kit I did to my then TK27 Carbs, back in 2003, then added a few more pictures and information later on.
smg.photobucket.com/user/CoreyClough/lib...0Jet%20Kit%20Install


Have fun with it, and get use to the looks and comments once on the road.

Do you mean the o ring on the fuel air mixture screw? (part#92055d)

The dyno jet seems like a good idea - if nothing else for the adjustable needle.

wow, some DIRTY carbs. take a look;







the ultrasonic cleaner has worked great so far.

Yes, the ones that go under the air mixture screws.

www.kawasaki.com/Parts/PartsDiagram/137617/1985/ZX550-A2





Also the fuel pipe o-rings need replacing as well, because if you do not replace them, they will leak on you. Don't worry about the o-rings on the vents between number 1 & 2 and the ones on 3 & 4. Here is the part number you want for the fuel pipe o-rings:
670B1507 "O" RING,7MM

Yikes! Those are some crusty looking carb bowls. Been sitting a while?

the guy I bought it from had ridden it some like that!
It would hardly run below 5k - after looking at those carbs I am sorry I started it at all.


do you think the float needles need replacing? they LOOK ok but I have always replaced them on my dirt bikes. the only way I know to get new ones it to buy the whole K&L kit.

thanks again!

Just my opinion, as I am not an expert, but I do have experience with these carbs, and I do not work for K&L,. Othere here have many more years of carb experience, so take in what they suggest as well. As much as you may not want to buy the K&L Kits, it might save you money because these float needle assemblies are included in the kits, along with many sealing o-rings, and mixture screws and their springs. Price them out from Kawasaki as a comparison. Inspect the slide diaphragms to make sure they are not torn.

Again, just my opinion, but if your float needles have rubber tips, they are very old. Look at the tip of that needle as well, and if you see a ring around it, replace all of those assemblies as a set. The new one is obviously in the middle below.

Carbs cleaned up, ready for re-assembly
Several parts on the way - 4 rebuild kits (mostly for the float needles), float bowl gaskets, all new bolts with hex head, lots of misc O-rings.

OK, been awhile and not as much progress as I hoped...but moving along.
Whats done;
Fork seals replaced, lots of clean up, new plugs, wires, carbs assembled, clip-ons installed.

Carbs rebuild and waiting for assembly;


Bike 'waiting' for me to get moving;



Carbs look great and are ready for re-install:


As it currently sits (clip ons installed);