Glad you said that about the seat. I was trying to wrap my head around how the rubber tip of the needle could wear out the brass seat. A guy in the sevice department at the local Honda/KTM shop told me that. As far as I could see the seat looked fine. Also the 6.5mm on the float height sounds much more in the ballpark to where mine is set at. I'll check it tomorrow. I first noticed the leaking when I was swaping main, and pilot jets. When I would screw the drain plug back on and turn the fuel on the fuel would start to pour out the bottom drain hose, and the one on the right side of the carb. After I would start the bike it would quite. But then I noticed it leaking when I was out riding when I stopped for a sec and I looked down and it was leaking then also. Plus since I got the bike one of the first thing I remarked about, was how bad the fuel economy was. Which makes sense if the fuel is poring out as I ride.
Is there anything beside to high of a float level that would be causing the fuel to flow out the hoses? I thought the bike was jetted kind of odd when I got it. It came from sea level in Texas. I'm at 4,500 feet in Montana so I figured it would be running a bit rich. It had the stock main jet, 40 pilot, but the clip on the needle was on the number one, leanest top position.
Thanks for the info.