TOPIC:

Would a set of 84 kz550 carbs work on the 80 kz550? they are TK but not the same as the TK22's on it

The throats are bigger on the later carbs, so the manifold mounting screws are farther apart on the later motors. They are too close together, on the early motors, to mount the later carbs.

where are you Jeff? I might have some but will have to look for them,

Dumb question but Is your choke working correctly?

Bit of a long shot, but some main jet numbering is different than others...i.e. a 100 main jet could be different sizes between manufactureres. Also some-one may have drilled it out oversize?

www.jetsrus.com/FAQs/FAQ_mikuni_vs_dynojet_vs_keihin_sizes.htm

also lou's informative page:

home.comcast.net/~loudgpz/GPZweb/TK22mai...22jetsAndDrills.html

There seems to be a discrepancy between the two links regarding the kehin / dynojet numbering convention.
Just going 102.5 to 105 made a big difference when tuning my TK's, I noticed one size out you know it, two sizes out and it is virtually unrideable at WOT.

Wow. You've put in some wrench time.

If it were my bike, I'd get on EBAY, buy the airbox, take the carbs back to all stock, put the needle on the middle clip, bump up the main jet to a OEM #94, and I suspect it'd run for you.

Good luck pal !

ill stop messing around and rebuilt the carbs first.....i found the o-ring in my 26mm and 29mm hardand some broken apart not to mention every other o-ring as well.
spent alot of time checking electrical , compresson , etc to find out the carbs were not sealing correctly.
will never mess with a old bike unless i rebuilt crabs and make sure they are working properly.