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Crazy float problem

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I have a 04 kx125...

Every single time that I pull the motor apart, and put it back together that carb will leak out the vent line...

The craziest thing is I NEVER mess with the carb when I pull the top end.

I usually drain the gas from the carb if it is gonna be sitting a while... this last time the bike was sitting for about 2 weeks, and I go to start it and the carb is overflowing like no other...

but another weird thing is, it doesn’t leak out of the overflow drain... it leaks from the one of the vents that come out of the side of the carb... this bike has always done this...

The first time it happened, I just set the floats to the specs in the service book... and I will still over flow like mad... so I did it again, and again... probably about 5 times... after that I took the book, and the carb to the mechanic at the Kawasaki dealer... he set it for me and it STILL overflowed... so after that I figured something was up, so I ordered a new needle and seat... put that in, same thing. so then I ordered a new float, but that in, same thing... so then I am getting really pissed right... so I just work with it, and just set the float by trial and error... well I eventually figured out the way this carb needs to be set, and every time it happens I just reset it to that setting...

but I just do not understand why this carb keeps on doing this... it does not have anything to do with the bike sitting, or not being run for along time, or draining the gas out the carb... the ONLY time this carb has done it is when I pull the cylinder...

I have tried lightly tapping on the carb with a soft hammer, trying to free up the float or what not, and that never works...

And after I set the float to what I learned to set it at it is fine, every once and a while I will forget to turn my gas off, and it sits all night and it has never leaked when it is set...

The way I learned to set it is to play with the float setting, then put on the bowl, just holding it up there then blow threw the fuel inlet, and if it just barely flows air is the only way it will not overflow.

And if you look at the book, it is completely different than the way they say to set it...

And it is weird that it drains out the vent... I have never had it come out of the overflow, and it is not that the overflow spout is plugged or anything...

I have come to the conclusion that something is messed up with this individual carb... because I have worked of bike with the exact same type of carb, and I set it according to the book, and they never have problems... only this...

Now ever time I rebuild the bike, and am constantly looking for gas to start leaking out... I don’t think there has been one time it hasent done it when I pull that top end... and id say ive had the top end off about 10-12 times, so its not like its just a fluke....

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Now, the last time i tried to set it i went to far, and no fuel got in... so now I just took it off, set it and it is overflowing again...

And it is not like a am making insanely huge changes with the float adjustment...

This carb is getting on my nerves...

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My kx250 did that, all I did was take the carb off, drained it upside down. put it back on and it stopped leaking when I turned the fuel on, usually when I had put the bike on its side in the garage. Like there was gas stuck over the bowl. good luck

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