Excellent build thread! Stumbling across a well documented build thread that goes start to finish, is like finding forgotten money in an old coat.
Great job OP keep up the good work.

 

you're getting really good at troubleshooting nagging issues, for sure. I hope your travels are drama-free.

 

Good find and in time.

I'm still wondering what caused the carburetor to overflow.
I've seen worn or damaged needles/seats, stuck floats, and gas logged floats (float has a pinhole and fills with gas) but it doesn't seem like that was the case for you.

Did you discover the leak goblin?

 

I was celebrating too early... there were no leaks yesterday night. I even rode about a mile before going to bed to check if everything alright. Yet today in the morning. I opened the petcock, the overflow started to leak again...have no idea what else could it be. No dirt, no debris, the needle isn't worn, rubber diaphragm is new, the carburetor was rebuilt a few months ago.Yet it still pouring gas like it's full throttle. At least it runs now. On the highway, you give the full throttle, rides fine. As soon as you slow down and stop, the overflow chamber gets flooded and it starts to leak again...I'm out of ideas.

Anyway, it looks like I ain't going anywhere today.

 

my 91 flooded, on occasion for years. adjusted float level till I got sick of it
I always had to be sure to shut off the gas petcock.
The float needle seat is not replaceable.
I purchased a later model carb from a twin cam, noticed it had a very deeper bowl.
swapped the carb , hasn't flooded in 15 years

 

Looks like I will have to do the same. Do you mind to share a link to the carb you bought?

 

So I took off the carb again. Took it apart. Again. Cleaned it. Again))) and found the leak goblin!




The demon in the details.

 

When I removed the ACCELERATOR PUMP DIAPHRAGM back in place the first time, I accidentally put it the other way around. The devil in the details. The diaphragm has a salient edge on the top side that should fit into the groove on the bottom of the float chamber. When I took it off the first time to check if it's ripped I didn't mention that edge and placed it upside down. And that caused the leak... picture shows the right way of putting it.

 

Hopped on the bike for a test run. After 12 miles, still no leaks. Will ride some more on the weekend, but it looks like I finally found and fixed the problem once and for all.

The carb needs a little adjustment thou. I mentioned with RMP over 2500 the engine sounds and shakes a bit differently than before. Not too much, yet I feel the difference. Or maybe I'm just paranoid after all that))) LOL

 

installed Badlands module today. Plugged it in without any problems and now my turn signals are finally flashing! Thank you!