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Finally got my jetting pretty dialed after replacing the jet tower seal and installing a JD kit. Thought all was well but yesterday at a 90mi dual sport ride I noticed fuel leaking from overflow.
Pulled the carb thinking it was dirt or something hanging up the floats. Found nothing. Adjusted the float height a bit more, think I’m at 21mm now! Still had issues throughout the day. Not consistent. Didn’t make sense. Floats, needle and even the needle holder clip are new. I’m thinking the seat is worn. Maybe too much play side to side? Or actual cone of seat is worn?
I’ve seen you can pull them out with a tap but can I find a new one somewhere?
Is it time to just scrap this carb and go RB?

What about the o ring that the seat seals with?

Hmmmmm. Could be but can I get the seat out without damage to check it? Also, the leak is not consistent so I doubt this is the problem.
Anyone know the correct part number for the float needle? Jets-R-us lists two different numbers. Maybe I got the wrong size? Got it from Rocky mountain so I would think it’s correct but you never know.

Have you tried the polishing the seat trick?

Yes, I polished the seat with metal polish on a q-tip in a drill. The seat looks ok, no pitting. If anything, there could be too much wiggle room for the float needle. That’s why I’m thinking it’s worn.

If you're leaking fuel out the overflows with your float height set to 21mm you got a problem somewhere. Is it the OEM PWK35 or an aftermarket carb? All PWK carbs use the same float needle, there is only one part# but Jets-r-us lists the part # and their SKU# (their own internal part #) together so it looks like 2 part #s. I'd suggest maybe a bad float but you say you put a new one in. With the carb off the bike you can close the float valve and see if you can suck air out the fuel inlet to check if it's sealing off or not. Sounds like your float needle is not seating correctly or the seat is damaged in some way.