I have a 1986 FZX700S Fazer, and I've got an issue with fuel pouring out of the overflows. I recently noticed dripping coming from around the float bowl covers, so I decided to just go ahead and rebuild the carburetors.
After getting into them, I found that there were no rebuild kits available for the carbs, so I was forced to purchase individual o-rings. I checked the needles, and found all of them to have soft rubber tips with no visible imperfections (magnified), and the Needle Seats were in good shape with no damage to the inlet screens.
After completely rebuilding the carburetors, I turned the key and allowed the fuel pump to pressurize the system (until it stopped pumping). I then turned the key off and let it sit for a bit and did it again. I checked for leaks, and found none.
I started cranking, with the starting lever pulled out, and after a few seconds the bike fired up and sounded good. However, while doing a thorough visual inspection, I noticed gas pouring out of the overflow tube onto the crankcase (an audible steady flow, not just drips). At that point, the engine started to bog and sputter and I shut it down.
I plan to pull the carbs back off and pull the float bowl covers to see if I can find anything obvious, but was wondering if anyone had any ideas. The obvious answer would be a stuck float not allowing a needle to close, but they were all in great shape and operated freely. The only other possibility I can come up with is one or more needle seats not properly sealing.
Any other ideas?
Thanks in advance!!