Kawasaki KZ 550 A1-A3, C1-C4, D1

Teikei TK-22 carburetor information.

BACK TO HOME






This page was started in June of 2011, and will be under construction for some time.

The Teikei brand, (known as "TK" brand outside of Japan), TK-21 and TK-22 carburetors are very similar. They were used on early Kawasaki KZ500, KZ550, and KZ400J (inline-four) motorcycles. The information on this page is for TK-22 carburetors, but some of it will apply to TK-21 carbs as well.

The TK-22 carbs are a mechanical-slide carb with a single main jet and a single pilot jet. All variations of those carbs are the same with the exception of the main jet, metering needles (same shape, but some were not adjustable), and air-screw settings. All used the same pilot jets. The U.S. models use the non-adjustable needle which is exactly the same as the adjustable needle set at the second clip from the top. The U.S. models also had caps covering the air screws to prevent users from adjusting the air screws.

On USA models using the TK-22 carbs, all internals are the same, with the exception of the main jet on the KZ550 D1, which was slightly larger.

Supposedly, slides with different cutaways exist, maybe for racing, but all of the KZ400, KZ500, and KZ550 with TK-21 or TK-22 carbs came with the same slides.

Most TK-22 carbs came in silver, but the KZ550D carbs were painted black. Possibly some of the later KZ550A carbs may have also been in black.


General Technical Specs
(See links below for part numbers, o-ring specs, jet dimensions, needle dimensions, and internal dimensions.)

This chart represents the models using TK21 or TK22 manual-slide carbs. Later models with CV type carbs are not represented here. The same bikes, made in subsequent years, using the same carbs most likely have the same internal setups. For example, the 1981 KZ550C2 and 1982 KZ550C3 would have the same setup as the 1980 KZ550C1, because they also use the TK22 carbs. However, the 1983 KZ550A4 uses different carbs than the 1980 KZ550A1, so its setup would have to be different.

Note: All models with TK21 and TK22 carbs have the same pilot jet, slide, and fuel levels.

The West German 550 model is puzzling since it is listed as having the smaller carb, yet the 500 has the larger carb. Maybe it's an error in the Factory service Manual, which is where most of this information came from.

Year & Model TK carb Main
Jet
Needle Clip pos.
from top
Pilot
Jet
Air screw
turns out
Slide Fuel design
level (mm)
Fuel service
level (mm)
1979 KZ500B1 K22P-2A 90 4C91-2 2 32 1-1/8, +/- 1/4 2.5 29.5, +/- 1 3.5, +/- 1
1980 KZ400J1 K21P-2A 90 4C91-2 2 32 1-1/4, +/- 1/4 2.5 29.5, +/- 1 3.5, +/- 1
1980 KZ400J1
West German
K21P-2A 92 4C91-2 2 32 1-1/2, +/- 1/4 2.5 29.5, +/- 1 3.5, +/- 1
1981 KZ550A1 and C1 K22P-2D 92 4D93-2 2 32 1-3/8, +/- 1/4 2.5 29.5, +/- 1 3.5, +/- 1
1981 KZ550A1 and C1
USA
K22P-2C 92 4D92 No Adjust 32 (1-3/8, +/- 1/4) 2.5 29.5, +/- 1 3.5, +/- 1
1981 KZ550A1 and C1
West German
K21P-2A 90 4C91-2 2 32 1-1/4, +/- 1/4 2.5 29.5, +/- 1 3.5, +/- 1
1981 KZ550D1 K22P-2F 94 4D93-2 2 32 1-3/8, +/- 1/4 2.5 29.5, +/- 1 3.5, +/- 1
1981 KZ550D1
USA
K22P-2E 94 4D92 No Adjust 32 (1-3/8, +/- 1/4) 2.5 29.5, +/- 1 3.5, +/- 1
1979 KZ500B1 K22P-2A 90 4C91-2 2 32 1-1/8, +/- 1/4 2.5 29.5, +/- 1 3.5, +/- 1


The bore of the carbs starts out round at the airhorn, then changes to a vertically elongated circle at the slide. The circle is about 19.9 mm in diameter, and is stretched vertically at the middle by 2.9 mm. The floor to roof distance is then approximately 22.8 mm (19.9 + 2.9). Then the bore changes back to circular at the exit port on the engine side.

The airhorn lip outside diameter is nominally 40 mm.
The airhorn lip inside diameter is nominally 37 mm.
The exit port outside diameter is nominally 29 mm.
The exit port inside diameter is nominally 24 mm.
The KZ550's have a carb spacing of 71 mm center-to-center for carbs 1-to-2, and 3-to-4.
The KZ550's have a carb spacing of 92 mm center-to-center for carbs 2-to-3.

Links to TK-22 pages:
Teikei corporation website in English.

TK-22 parts diagrams and part numbers.

TK-22 carb body port routing.

TK-22 fast-idle modification for choke system.

TK-22 jet dimensions, availability, and drilling.

TK-22 rebuild kits.

TK-22 jet kit.

TK-22 three types of needles.

TK-22 instructions for changing needles.

TK-22 shimming needles to get half-step increments.

TK-22 those darn choke flaps. What to do?

TK-22 adjustments and maintenance.


BACK TO HOME