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Adjust the float to the settings per the manual. If you don't have a manual the float height should be 0.413-0.453 or 10.49 to 11.51 mm. Mine is at 11.0 and runs fine. If no way to measure it then look at the float bottom, it should run parallel with the cast housing where the bowl screws on to.
I was going to guess pilot (slow) jet as well.
Nice to hear you have her up and running. I have a 94 fxd and I really like the ride and the rubber mount. The bike just fits and feels good. Kind of fell into the bike by chance, got a good deal, and so far I have been very happy with it.
I had the same problem with an aftermarket needle in my sportster. Check the thickness of the aftermarket needle. Might be hanging up as the aftermarket float needle I had was slightly thicker (fatter). Hard to tell from sight till I put a gauge on it. YD
I bought a rebuild kit for my cv a while back. After installing the new float needle, fuel over flowed. I fought with that problem for two days. I finally just put the old needle back in, ridges on the rubber and all. Problem solved. I have no idea why that new needle would not work. When I laid it side by side with the old one, there were a few minor differences, but nothing to prevent it from working. It had me stumped...still does. A guy gave me a cv he had around from an old bike. That carb had the same problem, I could not get it to stop over flowing. It's a puzzle I never solved.
I had the same thing happen to to me. After rebuilding the carb I chased float needle issues for a few days finally put the old one back and all was well. Same as you I could not see any major differences between the two but the new one just refused to cooperate.
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