Advice on this Kz550

On a 550 they are less prone to cracks, but my advice is to use a penetrating oil on the bolts for a few days and remove and inspect. If the have some age cracks you may need a magnifying glass to check them well. You can use some 800 grit sandpaper on a block and make the mating surface flush again. Then a paper gasket can be used or a very thin layer of silicone/sealer. Only put sealer on the mating area not ID and a very light amount. You can let it dry fully before reinstalling and the goo will not migrate. Put em back on and torque correctly. Way cheaper than replacement and if not cracked badly they will last a long time. Also for easier install, lightly grease the OD of the carb ports that go in the holders. Use sparingly, I spread it thin with a q-tip. I have 550 carb install vid on youtube.

There is a set of airbox ducts listed on eebbaayy right now. He says they're nice n soft.
search the part number or GPz550. $25T shipped.

Thanks, I found them. Hopefully I can snag before someone else does.

Quick question, this particular o-ring that is over the starter jet is listed as 92055A --- 92055-1126, however when I look at the picture that partzilla has for it. It appears to look like a different size oring. The one covering the starter jet should look like this one (borrowed from another thread)

Mcren wrote: Quick question, this particular o-ring that is over the starter jet is listed as 92055A --- 92055-1126, however when I look at the picture that partzilla has for it. It appears to look like a different size oring. The one covering the starter jet should look like this one (borrowed from another thread)

The two images you show seem to agree. How do they look different?

Here's the part on partzilla. It looks right. Image ref# 90255A is 92055-1126
www.partzilla.com/parts/detail/kawasaki/KP-92055-1126.html

According to their ruler for scale, the OD of the ring is about 3/8", very roughly.

Make sure you are looking at 92055A and not 92055.

Thanks loud, I'll use my caliper and compare. I took a picture before i headed out to work last night.

Maybe someone stuck in an oversize oring?

Possibly, I went ahead and ordered some new ones. Still I've been scratching my head on this one.

i was looking through some of the older posts about tk26 carbs. Seems there was an plug that goes over the pilot jet. None of the carbs had this plug when i first opened the carbs up.
kzrider.com/forum/11-projects/601960-198...o-again?limitstart=0

However why is it when i refer to kawa part list for the carb I see no p/n for this plug?
www.kawasaki.com/Parts/PartsDiagram/134990/1983/KZ550-A4
good thing is the correct main and pilot jets were in the carbs, 32main and 110 pilots in all four.

I see this is part is on the gpz model but not present in the kz , correct line of thought?

The TK-26 carbs have a few versions. The Gpz version is probably the older, and maybe that is why they are different. They figured out a different pilot system that didn't need the plug.

Other than the plug over the small jet, there is a tiny hole that transfers fuel from one circuit to the other. The ones without the plug don't have the transfer hole. You could confirm that hole is not there (with someone who knows where it would be), to be sure you don't need the plugs if you are worried about it.

Thanks loud Ill go off the parts fiche and go with it not being needed. I'm rebuilding the carbs slowly at the moment. The new orings came in I'll install them and update.

Few updates Carb rebuild probably about 85% done. Carbs all cleaned reganged, however my only concern is the oring we discussed earlier. I'm thinking the previous owner put in a different type of oring as the one in the parts fiche is completely different. I've attache the photo,( :laugh: I know I'm gonna get laughed at for my comforter.) The orings on the left are the ones the ordered, the one on the right are the ones I found in the carb. besides this the carbs can get the clear tube test at a later date once buttoned up.

I've also gone ahead and cleaned up the coils, measured the primary and secondary resistances. 2.4/2.5 , 11.8k/12k respectively. Hopefully can get a bit more life out of them.

Since I had both the coils and carbs off I thought now would be a proper time to do a compression test.

Initially the 12mm adaptor was binding on the spark threads so my intially readjng for the cyljnders 1 was low.
Dry comp.
Cyc 1. 90
Cyc 2 . 60
Cyc3 125
Cyc4 125
After a bit of fumbling around searching for my deep socket I was able to properly thread it.
Dry comp.
Cyc 1. 120
Cyc 2 . 65
Cyc3 125
Cyc4 125

A bit bummed out cyc2 compression is so poor low... In addition to the low readings across all 4.

I did not have any of the rated motor oil so I could not do it wet.

What would be the best oil to use?