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Tips for rebuilding my tk-22

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11 Jun 2013 17:16 - 11 Jun 2013 17:18 #591778 by BlackCafe
Tips for rebuilding my tk-22 was created by BlackCafe
Hey guys, just bought a '81 kz550 and am in the final stages of converting it into a little café racer. Right now I am attempting to rebuild all 4 carbs as It sat for a while with the previous owner and could use some love. Right now 3 of the 4 work but might as well redue them all while I have it torn apart. I have the rebuild kits already but was wondering if you guys had any tips on howto make the process a little smoother or any tips to ensure it is done properly. Let me know if you can help.
Also I will post before and after pics of the bike to show you how it looks. Im pretty happy so far.

1981 KZ550 LTDC, tk-22 carbs. modified into Cafe Racer.
Last edit: 11 Jun 2013 17:18 by BlackCafe. Reason: typo

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11 Jun 2013 18:36 #591786 by loudhvx
Replied by loudhvx on topic Tips for rebuilding my tk-22
Don't use carb spray until all of the rubber parts are out of the bottom end.

No need to separate the rack.

I have a tk22 site, link in my sig. Look into doing the fast-idle mod before putting it back on the bike.
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11 Jun 2013 19:38 #591804 by kimsmith4807
Replied by kimsmith4807 on topic Tips for rebuilding my tk-22
With any rebuild, no matter what part of the bike big or small, I take photos every step of the way. This makes for a good visual reference during assembly. A manual and/or a parts break down is always nice. Compressed air is also nice for blowing out some of the orifices. Take your time and get it right the first time. I have a buddy who is on his fourth go 'round with cleaning and he's still flushing crud out of them. Some of the varnish is so layered that a single pass with even the best cleaners isn't enough. Good luck and keep us posted.

1981 KZ1000-K1 LTD
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13 Jun 2013 17:49 #592126 by BlackCafe
Replied by BlackCafe on topic Tips for rebuilding my tk-22
Thanks for the tips. I got them taken apart and put back together. They were in desperate need. One of them actually had green mold growing in it. I still am not getting gas to the two throttle side carbs though. i spray carb cleaner in with the air filters off and they fire but will not get gas. I think there might be a problem with the fuel rail. Have you had any experience with this problem?

1981 KZ550 LTDC, tk-22 carbs. modified into Cafe Racer.

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20 Oct 2020 14:57 #837320 by Rustybucket
Replied by Rustybucket on topic Tips for rebuilding my tk-22
I’d replace the choke flaps while they’re apart. Only place I found that sells them is a guy on eBay. They’re about $30 for 4 of them and made from stainless steel instead of the crappy zinc coated steel.

I’d replace them even if yours are still good because they’re known for busting off.

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20 Oct 2020 15:05 #837321 by Nessism
Replied by Nessism on topic Tips for rebuilding my tk-22
I'm a strong proponent of a full break down of the carbs and soaking the bodies in carb dip. Do the job right once and you are done. I recently redid a set of TK-22's and posted a photo in another thread on this topic. I didn't replace the choke butterflys but I did stake the pins in place better and used some 3M epoxy as a reinforcement.

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21 Oct 2020 13:43 #837399 by loudhvx
Replied by loudhvx on topic Tips for rebuilding my tk-22
In my opinion, the zinc plated steel is slightly stronger, yet softer, so it forms better with less brittleness, and makes it easier to get out of the engine with a magnet. The stainless was used because it wouldn't need the extra steps of plating to prevent rust.

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