+1 again, I also cleaned the carb a few times & had no luck, When you open up the pilot jet hole it will run better

If the pilot jet is currently not really making any difference the hole is too blocked, My pilot jet was wound out past where it should be and made no real difference, After cleaning out the pilot hole it is now wound back in a few more turns and actually works, Cant remember the exact setting but you will need to fiddle with yours to get it right

Edited by XR250INOZ, 15 April 2012 - 02:15 PM.

Pulled the pilot jet out and ran a wire through all the holes. Didn't find anything clogged up. Pulled the choke out and that tube that runs down into the fuel bowl was plugged up. I didn't even know it was supposed to have a hole in the side of it. Got it all cleaned out and it starts up and runs nice!

Now I need to pull the right side cover off and find out why my kick start is messing up. Sometimes it won't catch and I have to put the bike in gear and turn the motor over. Has some broken teeth on one of the gears just have to find out which one.

The choke circuit only works obviously when the choke is on so if it is now running better without the choke on you have managed to clear the pilot circuit
Once warmed up & the choke is off does it now run better?

After I cleared my pilot circuit I pretty much dont need the choke now, I still use it though mainly to idle up when cold & warm it up, I can start it without the choke & it will start second or sometimes first kick even after sitting for a while

For my 400, I turn the idle screw like 1 turn faster (or even more) with the choke on and it starts right away. If I dont do it, it is very hard to start because it dies when I touch the throttle, just as you! I start riding and get it back to normal idle when the engine is hot ( the idle gets higher when warm)  Hope it helps!

So when you re-set the float height, it fired right up but still won't stay running longer than 10-15 sec when cold?  Is the pilot jet still stock, at 1 1/2 turns out?  I bet it would benefit from a larger pilot jet anyway... as said before these older XRs are jetted notoriously lean from the factory and should be re-jetted asap, and especially soon if it's got an aftermarket air filter or exhaust.  It goes without saying due to your various experience wrenching on bikes, but remember these dual-carb things have an air screw too.    Good luck and have fun... and please don't part it out, there are a lot of enthusiasts who appreciate these older bikes and would love to have one like your 250.

It starts up and runs great now. The pilot jet is sock side but the main jets are larger compared to the shop manual. Now my next problem is I pulled the right side cover off to see what was up with the kick start and the gear on the back of the clutch basket is all chewed up and so is the one next to it. Found a used basket assembly on ebay but I'm having trouble finding that other gear. Supposed to go riding sunday so hopefully I can get parts here asap

Just a quick update went riding with some friends at St Joe State Park last weekend and the bike ran great. Starts up on 1 or 2 kicks every time. Now I just need to learn to ride it better.

That's great to hear you got it running well.