Recheck the float level. Believe the carb needs to be angled at 15 to 20 degrees.

 

One word for ya:

Dave63

 

I would guess that the float needle stuck ! REPLACE the float needle, cleaning doesn't do a thing for a worn out needle !
If the petcock isn't shutting off fuel flow it should be replaced. As far as I could find only H-D supplies the vacuum petcock.

 

I had the same problem I rebuilt the carb and it still leaks so I replaced the vacuum operating petcock and now it don't leak a drop

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If you replaced the HD needle which is aluminum, and 4 sided with an aftermarket which is 3 sided and steel, they cause leaks.

Float level may be too high.

Float may be too heavy and needs to be replaced.

Float pin corroded and float sticking on it.

Tank vent line may be clogged. Tank builds pressure with engine heat, pushes it through petcock, pressuring the carb. Tank cant bleed it off.

Dirt in carb bowl. I've seen fuel lines deteriorate internally and release small bits into the carb.

Damaged needle Vinton tip.

Worn seat.

What bothers me is the carb leaking AFTER it sits in garage. That's when tank gets heated the most, sitting stationary over a hot engine. Fuel shouldn't be going into the carb then if the petcock is OFF or even with engine not running.

Suggest rebuilding petcock too, just due to age.

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Thanks guys, got some good ideas now on what to tackle. Will order new petcock, replace fuel lines, check float angle, & tank vent. I believe Dragonreapersrc nailed it.
I checked closely when re-building the carb: float valve seat, jet needle, etc; so don't think there is a problem there. I did not think of tank vent plugged/expansion from motor heat - some great analysis of the problem from Dave63. Thanks again, Jimmy

 

take the carb off and remove all the jets to see if theres any crap blocking the pin holes ,but it sounds like the float was sticking to me !just clean it up n remove any old varnish and dirt /debri in it .. just take some time and get it cleaned up real good..

 

I dissembled, cleaned, polished, poked wires in holes, leak-tested the float, & played with the carb for two days in the shop - it was like new (looked better that a new one). Parts that were not replaced were inspected under magnification.

 

And.........

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