05 klx 300 is the bike. Gas started to spew from the float bowl drain screw while out on the trail. First just thought maybe the screw loose. But screw was tight, bottomed out actually. Fuel still leaked. Tied a not in the hose but fuel ran out the overflow-- float not working right(?). So get back home and take carb out and apart. Cleaned jets ports, etc. while examining the float bowl noticed that air passed through the drain with screw in place, bought new screw but still passing air. Mechanic said there is a flat spot inside the screw hole. So I guess the float bowl shot, but no replacement through dealers. Now what?

 

If all else fails, I'd probably try some petroleum-resistant Permatex "gasket maker" on the screw threads. Might booger-up when you actually need to drain the bowl...but how often is that? I suppose the longer-term solution would be to drill, tap, use a very slightly larger drain screw.

 

This is why I come here! Outside the box thinking. I'll try the gasket maker and also look for a larger screw etc just n case. Thanks Jeff