TK-22 Jets

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The only source for TK-22 jets, in the stock size for Kz550A1-A3 and Kz550C1-C4 models, are in the rebuild kits . That is 92 for the mains, and 32 for the pilots. The jet size numbers are the orifice diameter in hundredths of a millimeter.

The KZ550 D model uses size 94 main jets and 32 pilots. There is no source, as yet, for actual TK22 main jets in size 94.

JetsRus carries some sizes of replacement TK-22 jets.
http://www.jetsrus.com/a_jet_kit_street/kawasaki_550_KZ550_1980-1983.htm
The pilots are the ones described as 23.6mm long.
The smallest pilot size they list is 32.5, which should be fine as a stock replacement for the 32. They also have two slightly larger sizes, which should be more than adequate for most applications.
The mains they have are slightly large for most applications using the stock airbox.

Some Keihin main jets and Dynojet main jets can be used as substitutes for main jet sizes slightly larger than stock, as mentioned below. Another option is drilling jets which has proven to work fine as long as they are done uniformly. That is described below as well.



Main Jets

Besides the Tk-22 main jets linked to above, there are at least two sources for main jet substitutes. These are small-head (99101-393) Keihin main jets or their equivalent, and Dynojet brand main jets. While they both will screw in, and use the same numbering convention as the TK22 carbs (jet number represents the I.D of the orifice in hundredths of millimeters), the internal location of the jet orifice is slightly different, and/or the length of the orifice is different. Because of this, using the same number in different types of jets may result in slight differences in mixture.



Pilot Jets

The following have been examined and found to be inadequate as substitutes:

Mikuni VM28/486 pilots are not a good substitute. They are overall longer. Their head diameter is reduced where it would seat in the carb body. The emulsifier tube is a smaller outside diameter (1.9mm) than the TK22 pilot's diameter (2.3mm). However, it may not need to be air tight.
Note: The Mikuni jet numbering system is not consistent with the Keihin/Dynojet/TK numbers. A #55 jet measured between .64 and .66 mm.

Mikuni N224.103 pilots are not a good substitue. They are overall longer. Their head diameter is reduced where it would seat in the carb body. The emulsifier tube is a larger outside diameter(2.45mm) than the TK22 pilot's diameter (2.3mm). It may not fit at all.
Note: The Mikuni jet numbering system is not consistent with the Keihin/Dynojet/TK numbers. A #35 jet measured between .53 and .57 mm.

Keihin N424-22 pilot (also sometimes just called a type 22) has a 5.5mm head, which is bigger than the TK-22 pilot's (5.0mm). Other details need to be checked, but these may possibly work if the head was turned down .5mm where it seats into the carb body.

Also maybe try to Search these pilot jets.
MGMP_JET45TK
or
Make: Kitaco
OEM#: 451-3090420
Product#: 4513090420



Another option to get larger TK pilot jets is to drill them. This works well and is relatively easy to do. Stock is #32 (.32mm). With just a minor change to the exhaust, a stock pilot will usually work fine. With major exhaust changes, or pod air filters, #34 or #37 (.34mm or .37mm) may be needed.



Air Jets

The air intake , G, for the pilot system is not actually a jet, but just a hole drilled into the carb body. That hole leads directly to the pilot air screw. The pilot screw determines the air flow to the pilot system and is adjustable, thus eliminating the need for a calibrated jet.

The main air jet, E, for the main jet system is located in the air horn of the carb body, directly in line with the main jet gallery.



Drilling Jets
Drilling jets is relatively easy. Since the orifice is already there, the drill is just shaving a small amount of brass. Usually it is best to mount the drill in a vise carefully, and just hold the jets by hand and let the bit pull itself into the jet. It will drill out very quickly, so it is important to use a very very low speed drill, and don't linger after the bit goes through. It is important that each jet takes about the same amount of time to drill out for uniformity.

The Drill
The drill required must have a few special capabilities. First, it must be able to turn very slowly. Somewhere in the range 100 rpm is preferrable, but a little faster may be ok. Next, it would be preferrable to have a trigger lock so it will stay on by itself. This way, you will have two hands for manipulating the jet if necessary, and you won't have to keep hold of the drill so it can be in a vise. Lastly, and most importantly, the chuck must go down to almost zero diameter. This is not usually possible on most drills and will be the most difficult feature to get. Luckily, in the U.S., Menards carries a drill that has all of these characteristics, and is also one of their lowest cost drills. It is the red "Tool Shop" brand.

Drill Bits
Obviously, very tiny drill bits are required to do the drilling. The most readily available set of tiny bits is probably the Forney Industries 60239 Mini Drill Set. It covers all of the sizes required for the TK22 up to 99 mains, and has the two smallest sizes required for the pilots (34 and 37).

The 60239 Mini Drill Set has the following sizes:
#80 bit = .0135" = .343mm = #34.3 jet
#79 bit = .0145" = .368mm = #36.8 jet
#78 bit = .0160" = .406mm = #40.6 jet
#77 bit = .0180" = .457mm = #45.7 jet
#76 bit = .0200" = .508mm = #50.8 jet
#75 bit = .0210" = .533mm = #53.3 jet
#74 bit = .0225" = .572mm = #57.2 jet
#73 bit = .0240" = .610mm = #61.0 jet
#72 bit = .0250" = .635mm = #63.5 jet
#71 bit = .0260" = .660mm = #66.0 jet
#70 bit = .0280" = .711mm = #71.1 jet
#69 bit = .0292" = .742mm = #74.2 jet
#68 bit = .0310" = .787mm = #78.7 jet
#67 bit = .0320" = .813mm = #81.3 jet
#66 bit = .0330" = .838mm = #83.8 jet
#65 bit = .0350" = .889mm = #88.9 jet
#64 bit = .0360" = .914mm = #91.4 jet
#63 bit = .0370" = .940mm = #94.0 jet
#62 bit = .0380" = .965mm = #96.5 jet
#61 bit = .0390" = .991mm = #99.1 jet

Here's a continuation of the number-sized drill bits:
#56 to #60 would be good to have for more modified GPZ's.
#60 bit = .0400" = 1.016mm = #101.6 jet
#59 bit = .0410" = 1.041mm = #104.1 jet
#58 bit = .0420" = 1.067mm = #106.7 jet
#57 bit = .0430" = 1.092mm = #109.2 jet
#56 bit = .0465" = 1.181mm = #118.1 jet
#55 bit = .0520" = 1.321mm = #132.1 jet
#54 bit = .0550" = 1.397mm = #139.7 jet
#53 bit = .0595" = 1.511mm = #151.1 jet
#52 bit = .0635" = 1.613mm = #161.3 jet
#51 bit = .0670" = 1.702mm = #170.2 jet
#50 bit = .0700" = 1.778mm = #177.8 jet
#49 bit = .0730" = 1.854mm = #185.4 jet

Here is a comprehensive drill size list.
Click here for printable drill chart pdf.
Drill size Diameter (in) Diameter (mm)
#107 0.0019 0.0483
0.05 mm 0.0020 0.0500
#106 0.0023 0.0584
#105 0.0027 0.0686
#104 0.0031 0.0787
#103 0.0035 0.0889
#102 0.0039 0.0991
0.1 mm 0.0039 0.1000
#101 0.0043 0.1092
#100 0.0047 0.1194
#99 0.0051 0.1295
#98 0.0055 0.1397
#97 0.0059 0.1499
#96 0.0063 0.1600
#95 0.0067 0.1702
#94 0.0071 0.1803
#93 0.0075 0.1905
0.2 mm 0.0079 0.2000
#92 0.0079 0.2007
#91 0.0083 0.2108
#90 0.0087 0.2210
#89 0.0091 0.2311
#88 0.0095 0.2413
#87 0.0100 0.2540
#86 0.0105 0.2667
#85 0.0110 0.2794
#84 0.0115 0.2921
0.3 mm 0.0118 0.3000
#83 0.0120 0.3048
#82 0.0125 0.3175
#81 0.0130 0.3302
#80 0.0135 0.3429
#79 0.0145 0.3680
1/64 in 0.0156 0.3969
0.4 mm 0.0158 0.4000
#78 0.0160 0.4064
#77 0.0180 0.4572
0.5 mm 0.0197 0.5000
#76 0.0200 0.5080
#75 0.0210 0.5334
#74 0.0225 0.5715
0.6 mm 0.0236 0.6000
#73 0.0240 0.6096
#72 0.0250 0.6350
#71 0.0260 0.6604
0.7 mm 0.0276 0.7000
#70 0.0280 0.7112
#69 0.0292 0.7417
#68 0.0310 0.7874
1/32 in 0.0313 0.7938
0.8 mm 0.0315 0.8000
#67 0.0320 0.8128
#66 0.0330 0.8382
#65 0.0350 0.8890
0.9 mm 0.0354 0.9000
#64 0.0360 0.9144
#63 0.0370 0.9398
#62 0.0380 0.9652
#61 0.0390 0.9906
1 mm 0.0394 1.0000
#60 0.0400 1.0160
#59 0.0410 1.0414
#58 0.0420 1.0668
#57 0.0430 1.0922
1.1 mm 0.0433 1.1000
#56 0.0465 1.1811
3/64 in 0.0469 1.1906
1.2 mm 0.0472 1.2000
1.3 mm 0.0512 1.3000
#55 0.0520 1.3208
#54 0.0550 1.3970
1.4 mm 0.0551 1.4000
1.5 mm 0.0591 1.5000
#53 0.0595 1.5113
1/16 in 0.0625 1.5875
1.6 mm 0.0630 1.6000
#52 0.0635 1.6129
1.7 mm 0.0669 1.7000
#51 0.0670 1.7018
#50 0.0700 1.7780
1.8 mm 0.0709 1.8000
#49 0.0730 1.8542
1.9 mm 0.0748 1.9000
#48 0.0760 1.9304
5/64 in 0.0781 1.9844
#47 0.0785 1.9939
2 mm 0.0787 2.0000
#46 0.0810 2.0574
#45 0.0820 2.0828
2.1 mm 0.0827 2.1000
#44 0.0860 2.1844
2.2 mm 0.0866 2.2000
#43 0.0890 2.2606
2.3 mm 0.0906 2.3000
#42 0.0935 2.3749
3/32 in 0.0938 2.3813
2.4 mm 0.0945 2.4000
#41 0.0960 2.4384
#40 0.0980 2.4892
2.5 mm 0.0984 2.5000
#39 0.0995 2.5273
#38 0.1015 2.5781
2.6 mm 0.1024 2.6000
#37 0.1040 2.6416
2.7 mm 0.1063 2.7000
#36 0.1065 2.7051
7/64 in 0.1094 2.7781
#35 0.1100 2.7940
2.8 mm 0.1102 2.8000
#34 0.1110 2.8194
#33 0.1130 2.8702
2.9 mm 0.1142 2.9000
#32 0.1160 2.9464
3 mm 0.1181 3.0000
#31 0.1200 3.0480
3.1 mm 0.1221 3.1000
1/8 in 0.1250 3.1750
3.2 mm 0.1260 3.2000
#30 0.1285 3.2639
3.3 mm 0.1299 3.3000
3.4 mm 0.1339 3.4000
#29 0.1360 3.4544
3.5 mm 0.1378 3.5000
#28 0.1405 3.5687
9/64 in 0.1406 3.5719
3.6 mm 0.1417 3.6000
#27 0.1440 3.6576
3.7 mm 0.1457 3.7000
#26 0.1470 3.7338
#25 0.1495 3.7973
3.8 mm 0.1496 3.8000
#24 0.1520 3.8608
3.9 mm 0.1535 3.9000
#23 0.1540 3.9116
5/32 in 0.1563 3.9688
#22 0.1570 3.9878
4 mm 0.1575 4.0000
#21 0.1590 4.0386
#20 0.1610 4.0894
4.1 mm 0.1614 4.1000
4.2 mm 0.1654 4.2000
#19 0.1660 4.2164
4.3 mm 0.1693 4.3000
#18 0.1695 4.3053
11/64 in 0.1719 4.3656
#17 0.1730 4.3942
4.4 mm 0.1732 4.4000
#16 0.1770 4.4958
4.5 mm 0.1772 4.5000
#15 0.1800 4.5720
4.6 mm 0.1811 4.6000
#14 0.1820 4.6228
#13 0.1850 4.6990
4.7 mm 0.1850 4.7000
3/16 in 0.1875 4.7625
4.8 mm 0.1890 4.8000
#12 0.1890 4.8006
#11 0.1910 4.8514
4.9 mm 0.1929 4.9000
#10 0.1935 4.9149
#9 0.1960 4.9784
5 mm 0.1969 5.0000
#8 0.1990 5.0546
5.1 mm 0.2008 5.1000
#7 0.2010 5.1054
13/64 in 0.2031 5.1594
#6 0.2040 5.1816
5.2 mm 0.2047 5.2000
#5 0.2055 5.2197
5.3 mm 0.2087 5.3000
#4 0.2090 5.3086
5.4 mm 0.2126 5.4000
#3 0.2130 5.4102
5.5 mm 0.2165 5.5000
7/32 in 0.2188 5.5563
5.6 mm 0.2205 5.6000
#2 0.2210 5.6134
5.7 mm 0.2244 5.7000
#1 0.2280 5.7912
5.8 mm 0.2284 5.8000
5.9 mm 0.2323 5.9000
A 0.2340 5.9436
15/64 in 0.2344 5.9531
6 mm 0.2362 6.0000
B 0.2380 6.0452
6.1 mm 0.2402 6.1000
C 0.2420 6.1468
6.2 mm 0.2441 6.2000
D 0.2460 6.2484
6.3 mm 0.2480 6.3000
1/4 in 0.2500 6.3500
E 0.2500 6.3500
6.4 mm 0.2520 6.4000
6.5 mm 0.2559 6.5000
F 0.2570 6.5278
6.6 mm 0.2598 6.6000
G 0.2610 6.6294
6.7 mm 0.2638 6.7000
17/64 in 0.2656 6.7469
H 0.2660 6.7564
6.8 mm 0.2677 6.8000
6.9 mm 0.2717 6.9000
I 0.2720 6.9088
7 mm 0.2756 7.0000
J 0.2770 7.0358
7.1 mm 0.2795 7.1000
K 0.2810 7.1374
9/32 in 0.2813 7.1438
7.2 mm 0.2835 7.2000
7.3 mm 0.2874 7.3000
L 0.2900 7.3660
7.4 mm 0.2913 7.4000
M 0.2950 7.4930
7.5 mm 0.2953 7.5000
19/64 in 0.2969 7.5406
7.6 mm 0.2992 7.6000
N 0.3020 7.6708
7.7 mm 0.3032 7.7000
7.8 mm 0.3071 7.8000
7.9 mm 0.3110 7.9000
5/16 in 0.3125 7.9375
8 mm 0.3150 8.0000
O 0.3160 8.0264
8.1 mm 0.3189 8.1000
8.2 mm 0.3228 8.2000
P 0.3230 8.2042
8.3 mm 0.3268 8.3000
21/64 in 0.3281 8.3344
8.4 mm 0.3307 8.4000
Q 0.3320 8.4328
8.5 mm 0.3347 8.5000
8.6 mm 0.3386 8.6000
R 0.3390 8.6106
8.7 mm 0.3425 8.7000
11/32 in 0.3438 8.7313
8.8 mm 0.3465 8.8000
S 0.3480 8.8392
8.9 mm 0.3504 8.9000
9 mm 0.3543 9.0000
T 0.3580 9.0932
9.1 mm 0.3583 9.1000
23/64 in 0.3594 9.1281
9.2 mm 0.3622 9.2000
9.3 mm 0.3661 9.3000
U 0.3680 9.3472
9.4 mm 0.3701 9.4000
9.5 mm 0.3740 9.5000
3/8 in 0.3750 9.5250
V 0.3770 9.5758
9.6 mm 0.3780 9.6000
9.7 mm 0.3819 9.7000
9.8 mm 0.3858 9.8000
W 0.3860 9.8044
9.9 mm 0.3898 9.9000
25/64 in 0.3906 9.9219
10 mm 0.3937 10.0000
X 0.3970 10.0838
Y 0.4040 10.2616
13/32 in 0.4063 10.3188
Z 0.4130 10.4902
10.5 mm 0.4134 10.5000
27/64 in 0.4219 10.7156
11 mm 0.4331 11.0000
7/16 in 0.4375 11.1125
11.5 mm 0.4528 11.5000
29/64 in 0.4531 11.5094
15/32 in 0.4688 11.9063
12 mm 0.4724 12.0000
31/64 in 0.4844 12.3031
12.5 mm 0.4921 12.5000
1/2 in 0.5000 12.7000
13 mm 0.5118 13.0000
33/64 in 0.5156 13.0969
17/32 in 0.5313 13.4938
13.5 mm 0.5315 13.5000
35/64 in 0.5469 13.8906
14 mm 0.5512 14.0000
9/16 in 0.5625 14.2875
14.5 mm 0.5709 14.5000
37/64 in 0.5781 14.6844
15 mm 0.5906 15.0000
19/32 in 0.5938 15.0813
39/64 in 0.6094 15.4781
15.5 mm 0.6102 15.5000
5/8 in 0.6250 15.8750
16 mm 0.6299 16.0000
41/64 in 0.6406 16.2719
16.5 mm 0.6496 16.5000
17 mm 0.6693 17.0000
43/64 in 0.6719 17.0656
11/16 in 0.6875 17.4625
17.5 mm 0.6890 17.5000
45/64 in 0.7031 17.8594
18 mm 0.7087 18.0000
23/32 in 0.7188 18.2563
18.5 mm 0.7284 18.5000
47/64 in 0.7344 18.6531
19 mm 0.7480 19.0000
3/4 in 0.7500 19.0500
49/64 in 0.7656 19.4469
19.5 mm 0.7677 19.5000
25/32 in 0.7813 19.8438
20 mm 0.7874 20.0000
51/64 in 0.7969 20.2406
20.5 mm 0.8071 20.5000
13/16 in 0.8125 20.6375
21 mm 0.8268 21.0000
53/64 in 0.8281 21.0344
27/32 in 0.8438 21.4313
21.5 mm 0.8465 21.5000
55/64 in 0.8594 21.8281
22 mm 0.8661 22.0000
7/8 in 0.8750 22.2250
22.5 mm 0.8858 22.5000
57/64 in 0.8906 22.6219
23 mm 0.9055 23.0000
29/32 in 0.9063 23.0188
21/23 in 0.9130 23.1913
59/64 in 0.9219 23.4156
23.5 mm 0.9252 23.5000
15/16 in 0.9375 23.8125
24 mm 0.9449 24.0000
61/64 in 0.9531 24.2094
24.5 mm 0.9646 24.5000
31/32 in 0.9688 24.6063
25 mm 0.9843 25.0000
63/64 in 0.9844 25.0031
1 in 1.0000 25.4000
25.5 mm 1.0039 25.5000
1 1/64 in 1.0156 25.7969
26 mm 1.0236 26.0000
1 1/32 in 1.0313 26.1938
26.5 mm 1.0433 26.5000
1 3/64 in 1.0469 26.5906
1 1/16 in 1.0625 26.9875
27 mm 1.0630 27.0000
1 5/64 in 1.0781 27.3844
27.5 mm 1.0827 27.5000
1 3/32 in 1.0938 27.7813
28 mm 1.1024 28.0000
1 7/64 in 1.1094 28.1781
28.5 mm 1.1221 28.5000
1 1/8 in 1.1250 28.5750
1 9/64 in 1.1406 28.9719
29 mm 1.1417 29.0000
1 5/32 in 1.1563 29.3688
29.5 mm 1.1614 29.5000
1 11/64 in 1.1719 29.7656
30 mm 1.1811 30.0000
1 3/16 in 1.1875 30.1625
30.5 mm 1.2008 30.5000
1 13/64 in 1.2031 30.5594
1 7/32 in 1.2188 30.9563
31 mm 1.2205 31.0000
1 15/64 in 1.2344 31.3531
31.5 mm 1.2402 31.5000
1 1/4 in 1.2500 31.7500
32 mm 1.2598 32.0000
1 17/64 in 1.2656 32.1469
32.5 mm 1.2795 32.5000
1 9/32 in 1.2813 32.5438
1 19/64 in 1.2969 32.9406
33 mm 1.2992 33.0000
1 5/16 in 1.3125 33.3375
33.5 mm 1.3189 33.5000
1 21/64 in 1.3281 33.7344
34 mm 1.3386 34.0000
1 11/32 in 1.3438 34.1313
34.5 mm 1.3583 34.5000
1 23/64 in 1.3594 34.5281
1 3/8 in 1.3750 34.9250
35 mm 1.3780 35.0000
1 25/64 in 1.3906 35.3219
35.5 mm 1.3976 35.5000
1 13/32 in 1.4063 35.7188
36 mm 1.4173 36.0000
1 27/64 in 1.4219 36.1156
36.5 mm 1.4370 36.5000
1 7/16 in 1.4375 36.5125
1 29/64 in 1.4531 36.9094
37 mm 1.4567 37.0000
1 15/32 in 1.4688 37.3063
37.5 mm 1.4764 37.5000
1 31/64 in 1.4844 37.7031
38 mm 1.4961 38.0000
1 1/2 in 1.5000 38.1000

Click here for printable drill chart pdf.


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