Petcock Rebuild

[DEEBS11]

Try installing your carbs without the airbox and feed carbs directly with fuel. You will see the offending carb(s) leaking soon after. Adjust the float until the carbs don't leak. If you are using Chinese carb parts you will most likely not be able to stop this breech.

[Supersport396]

The rotors appear to be well centered. I'll check the splooge hole.

The fuel overflow stopped during road test. I'll have to look further. Thanks for the replies, appreciate it!

[DEEBS11]

Just to give you the heads up on what's happening here, years ago, a work friend with an 86 GSXR1100 wanted to convert from DOT4 to DOT5 fluid (which I recommended he not do because it really buys nothing of any real value on the common street bike). So, he emptied and flushed with DOT5 and air bled the hydraulic system. He rode the bike to work the next day to show me. By quitting time (4:00PM) his entire brake system was locked up and he could not move the bike out of the parking space. I had to let air into the system just to release the calipers. I looked at him and said "Now do believe me?".

When most people do this conversion, they don't fully remove all DOT4 fluid which entails disassembling master cylinders and calipers and cleaning all rubber and metal parts with brake cleaner. Then you need to flush all the lines with brake cleaner as well. THEN you reassemble and flush the system with DOT5. I'm pretty sure your system is "swelling" under contamination.

[Supersport396]

The PO did the DOT5 upgrade. I've had my own experiences with DOT5. Presently on an old corvette I converted 10 years ago, one caliper started leaking. After several rebuilds & then a replacement it would not stop the leak. So presently I rebuilt everything, flushed all lines with denatured alcohol and went back to DOT3. This isn't from swelling though because all new seals leaked on the one caliper within days. There's something about DOT 5 like the molecules are smaller or something. Swelling is a longer term problem. I am not a fan and will likely do the same to this bike next winter. The DOT5 rebuild was done last year so hopefully I can get a year out of it.