Leaking Super G

[econnor]

I have a Super G that has been on the bike since 97 No issues, had a master rebuild kit installed back 2004, only because the engine was being stroked, and it seemed like a good time to do it.

Out of the blue last week it started leaking gas and getting progressively worse. The leak started at the overflow hose and got progressively worse, now it is overflowing so bad that gas is coming out the vent hole on the air cleaner mounting surface.

I figured it was a bad float valve and seat, so I replaced them. Still leaks, no change. Next thought was a bad float, you know not coming up all the way, so I replaced it and the carb still leaks.

Other than this gas leak issue, this G has been maintenance free for many years. Nothing has been changed recently to attribute to this new leak.

Any ideas?

[econnor]

Also, the float is not binding in any way.

[kennyflhr]

Did you check the float hight?

[econnor]

Problem is fixed. The original float had a leak. The replacement float was way out of adjustment. After adjusting the float height everything is right again. While I had everything apart I went ahead and changed a bunch of the o-rings and gaskets in the carb/manifold area. Also went ahead and lubed the throttle cables. Funny how your bike has a way of telling you something's wrong.

Interesting, though how the overflow line does not have the capacity to keep up with the incoming fuel line. With an inoperable fuel float the gas really pours out the carb vent hole.

[econnor]

I thought the problem was fixed, until I went for a ride at lunch today. Turned on the petcock and gas was pouring out of the air cleaner. This got me thinking. Yesterday I had the carb off the bike, taken completely apart, set float height, replaced gaskets and o-rings. Shouldn't have had any issues. I spent last year doing a total rebuild of the bike. Cut the fender struts off, different sheet metal (to replace the mangled stuff after the wreck). Anyway, the vapor valve was in backwards/upside down. So it would let air in instead of letting it out like it is supposed to. I believe the gas overflow issue is attributed to the vapor valve and the bike being parked in the sun. Will confirm tommarrow at lunch.