So, CT, what you are saying is that no matter if the petcock is on fully or getting some kind of leak-by, the needle and seat if properly sealing, is supposed to stop the flow of fuel regardless? there isnt enough gravity pressure to push the needle out of the way, I guess that makes total sense, otherwise everyone of these bikes would leak, how many times have we parked our bikes and not turned the fuel off.

yes, I have set the floats to 23mm, granted I am using a 32nds scale as I dont have a mm scale that will work, that could be the issue.

I have also checked the floats, first by shaking to see if I can hear anything ( even got a pair of young ears to listen as well), submerged the floats in cold water looking for bubbles, submerged them in hot water, reasoning that any air in the floats would expand in the heat and escape more visibly...no leaks, no fuel sloshing around and they bob right to the surface.

Maybe its a bad seat, although its brand new it could be defective, its just wierd, rebuilt the carb about 1 1/2 months ago, all was fine...then this after a good long ride.

Maybe the float is binding and not seating the needle

Keep the ideas coming, these carbs are not that hard but they sure do cause more gray hairs

Its raining here today so will be easy to spend some shop time.....AGAIN!

Steve