When the float needle gets some wear it tends to stick in the seat. Time to replace it, or if you're cheap like me, just chuck it up in the lathe and recut the seat to clean it up. I'll make a tool to burnish & lap the brass seat and it'll be good to go. You'll need to adjust the float level slightly.
I've also had the same problem with a rubber-tipped seat. Our "new and improved" (!?@&$@!) gasolines with ethanol will attack the rubber tip and make it swell, thus sticking shut. Metal float needles only from now on.
Have you been following the recommended procedure of shutting off the fuel and letting the pony run out until it dies?
I bet that's it, dam ethanol in the fuel making the tip swell - I shall investigate tomorrow later on and report back.
OM, yes I do normally let the pony stop via fuel exhaustion, but I've an idea the the tap isn't 100% good and over time allows the carb to fill again. Again, I'll be doing a bit of investigation!
Thanks.
Julian.