kz550 choke flaps

Well I got something figured out. I am working on travis' bike. I tore the carb choke plates out and thought HRMMMM.. and then it hit me.. just somethign flat.... the original flaps had two tabs that bent around the pin on the choke.

So I grabbed a box cutter. and removed the outer case.


i125.photobucket.com/albums/p56/bwife1/kz550/DSC00153.jpg

Cut it out and formed this


i125.photobucket.com/albums/p56/bwife1/kz550/DSC00162.jpg



I just pulled the pin out removed the old pieces.. put the new flap in.. put the pin in and formed the extra tab over the top. I am thinking of seeing if I can solder the tab to the flap to make it totally secure. but it is secure as it is.

The whole set of pics are at

s125.photobucket.com/albums/p56/bwife1/kz550/

If someone has questions shoot me an email.

This flap works and is spring tensioned. I put pictures showing the dimensions. Maybe I am missing out on the $$$$$ to be made by the billions of TK carb owners that need flaps.. LOL yeah right.

Post edited by: mstbone67a, at: 2007/04/10 13:14

double post sorry..

Post edited by: mstbone67a, at: 2007/04/10 13:10

Excellent fine work on the TK flappers there.
I was fortunate enough to have all flaps intact on my 81 GPz when I got it, and do have a spare set of carbs in case of "flap eating" on the part of the engine...:laugh:
I like your solution, craftsmanship and creativity.

This flap works and is spring tensioned. I put pictures showing the dimensions. Maybe I am missing out on the $$$$$ to be made by the billions of TK carb owners that need flaps.. LOL yeah right.

I am one of the billions, but sadly...no order from me.

Very nice! Great photos and work! Let us know how it runs.

Incidently, have a look at this for tuningthe choke operation. This makes it so much easier to setup:
home.comcast.net/~loudgpz/GPZweb/TK22mai...astIdleScrewMod.html

Kz550 choke flaps for sale:
www.kzrider.com/forum/23-for-sale/594757...t-original-equipment

Some guy on eBay sells stainless steel flaps he has a machine laser cut and he bends himself and let me tell you that they were reasonably priced and fit perfect.
I was able to replace all the flaps while the carbs were on the bike in 30 minutes and it's a good thing i did. One of the hinge curls was on the verge of getting sucked into the motor.

If you still have the old steel flaps then replace them now! it's just a matter of time before you risk damage to the engine over something cheap and easy to fix.
I don't know how many are left but it's the only place that I've seen these things where they look good and was the exact thickness plus stainless steel so these will last forever.

I've seen where people would glue pieces and turn it into a manual choke. I wouldn't recommend because fuel will eat at the glue and now you'll have glue AND small pieces of metal going into the combustion chamber risking the cylinder walls being scored.

I've attached the instructions that they had on eBay. Hope this helps.