I just went through this. Here is what I did.
My bike was going through an obscene amount of fuel while woods riding. There is no way it could have burned that much fuel so I thought there is something to this overflow/float height thing. I read the whole thread on jetting, researched the special float height tool, called sudco to find out how much bowl plugs cost and researched the Keihin method of setting the float height. After all this research I decided to go with KXCams "blow through the tubing method."
When I talked to sudco they said the most overlooked and most important part of the carb is the float needle. It is not cheap. I paid $18. He is sudco, he knows more than me so I went with it along with a handful of pilot jets. Your overflow problem may be related to a wore out float needle.
The float height is supposed to be 16mm +-1 from the gasket surface to the part of the float farthest from the gasket surface. After reading KXCams contribution to the jetting thread I decided to set the float 1mm below the suggested range ie. 18mm.
I put fuel line onto the carb fuel inlet port. While holding the carb upright, I blew through the fuel line as I slowly raised the float until the float needle engaged the seat which cut off the air I was blowing in the fuel line. At the point where the air stopped, I held the float steady against the center guts of the carb and measured the float height with a caliper. I repeated this with the carb in various attitudes to make sure my method was consistent. I tweaked the tab until my distance was a solid 18mm and called it good.
I went out riding tonight and went through much less fuel. It still goes through more fuel than what I think it should for woods riding. I am still rich on the pilot. I am hopeful that getting the pilot right will further enhance the range. If not, I may go another mm on the float height??
Hope this helps.
Fitz
