What dealer in NJ?
Ok, we will assume the float needle seat and oring are fine. the float is not set too high (the lower the number, the higher the float).
The next thig is the carb drain/overflow which is the hose on the bottom of the bowl.. This hose does double duty, serving as the drain point for the float bowl and a point for overflow ( remenber the brass tube in the float bowl?) If fuel is coming from that, pull the hose up into a 'U' shape along side the carb. Turn the petcock on. If fuel rises in it and stops at about the gasket line on the float bowl, the drain screw is not sealing. If it rises further than that, it is still a float needle seat issue.
I really do appreciate all your time and effort in trying to help me here.
I went to Action Yamaha in Edison/Metuchen and sat down with Kurt.
BTW, I just got the replacement seat from Sudco - it looks nothing like the original valve seat in my carb. I was kind of expecting this. Below is a picture of the replacement, which is part # N361-03-3.80 (you can see 3.8 stamped on my original valve seat on one of the pictures I posted earlier in this thread)
So, I went out to try to overflow tube test - turned on petcock - no leaks. Start it up, no leaks. I've had the petcock open for the past 25 minutes. Not a drop. I've been jumping up and down on the pegs trying to get this thing to leak...no dice. I think this bike just hates me.
I went to Jersey for 3 days, and had the petcock Off, and there was a puddle on the mat when I came home yesterday.
So, for right now, I cannot get the fuel to leak in order to perform the test (which is a neat test, by the way). If it starts to leak, I'll post the results.