I have a Kawasaki KDX200 shifter kart with a Keihin PWK 36 that has the pump around mod with the dual Mikuni round pumps.
The system was overflowing pretty bad so I rebuilt the return pump but it is still happening. I had it running on the stand and I removed the tank cap I could see the fuel being returned but it obviously isn’t keeping up.
Thanks Gerry. The overflow happens with the tank cap on or off. I took the carb back off and have it on the workbench right now. I can tap the return pick up down but I’m not sure how far or where it should be. I’ve tried googling for pictures but no luck.
I am a newbie in shifters and pump around, so it may not be the solution and I was lucky, but I was experiencing the exact same problem and by changing the foam inside the carb did the trick. I have no more overflow…