Could it be the angle at which they sit on the bike is just at the wrong spot causing the floats to not close the float needles? Those float needles are tricky sometimes. They might even need to be replaced. I know you said you cleaned it, but even the tiniest piece of fiber can cause problems at the float needle seat.
Aaron
04 "Green Bean" Freaked, AI removal, Bafflectomy, 6" Risers, and 30" Drag Bars.
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