The return line is to keep from having too much dead-head pressure at the carb, AND it helps cool the fuel so vapor lock isn't an issue.
If you're just looking at the fuel going back thru the return line, it may seem like a lot, but consider that the carb doesn't really need an abundant flow of fuel while idling.
You may need to install a fuel pressure gauge
at the carb and drive it, and see what the pressure is when the problem appears. You may also want to block the return line for a test and see if it has any effect,and maybe even leave the gas cap loose.
Have you blown thru the actual fuel supply line from the tank to the pump, or otherwise checked it for restrictions? How about the rubber line from the frame to the pump? Is there a kink in it?
Seems like we're all looking for a fuel problem, when it may not be one. The pressure reading will confirm that. If the fuel pressure is not dropping when the problem occurs, the the fuel system is fine, and we need to concentrate on another area...
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Joel Adams
C3VR Lifetime Member #56
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