I just finished a carb cleaning/rebuild on a kawi ex500. I had a major gas leak with the overflow and the jet ports on the airflow side. I corrected the overflow issue as the float heights are at factory level but I have a fairly steady stream of gas still flowing from both jet ports and can't seem to figure out why. Any thoughts or suggestions would be helpful.

 

What is the outside temperature if the engine is at rest when this is happening? I am looking at a tank vent issue possibly on mine (sounded like the same scenario), but since it is zero degrees right now, that is not happening.

 

They'll do that if the float needle and seat need replacing. Scored needle tips or seats will pass fuel all the time instead of shutting off when the float bowl is full and if the float is sticking down it will continually dribble fuel out the overflow and even into the air box.

 

so true. You would see a faint ring normally on the needle. A cheap and easy change out.