'96 KDX200 Jetting Issues, Need Help!!!

[KDX Dad]

Ok, I need help.
I have maybe one of the cleanest '96 200s around (still on the original tyres) and I just can't get it to run worth a darn.
When I bought it the PO had a 35 pilot jet in it along with a different needle and it never really ran right. There always some transition issues between pilot and needle.
I installed the proper 45 and put the stock needle back in and now it runs like dog-doo. It's basicly a 1/2 throttle and up kinda bike now. It'll idle when first started but not after it warms up. This is all pointing to a very rich condition, even tho I'm following the time tested jetting specs from JustKDX.
Bike has a stock expansion chamber, FMF silencer and I'm guessing that there was a small snorkle on the airbox lid but now it's just a trapezoidal hole that looks to be factory.
Any thoughts?
Thanx.

 

[G. Gearloose]

You must first identify you needle, else choosing a pilot is moot.

 

[KDX Dad]

Sorry, the needle is the stock one and is new. Changing clip positions has a minimal effect since the pilot is so far outta whack...
Float height is correct and the carb is clean.
Thanx!

 

[Oskar]

I run my 96 w/a 45 and 155 jets and stock needle on 2nd from the top position. It's a beast.

 

[KDX Dad]

I was sorta fishing around to see if there was a common mod that would make the bike want such a smaller pilot.
I've got more time now that I'm home from deployment instead of just on leave. I'm seeing a call to Sudco in my future, with a set of pilot jets being sent my way. I'll also dig in deeper to look a the reeds and what-not.
Thanx.

 

[SVandal]

Have you checked your choke assembly? Don't know that I have ever heard anyone having problems with one, but it does fit the description of the problem.

 

[Ogre]

How caked full of carbon is the stock chamber?

 

[AwfulSmokey]

Use the air screw to tune it in. If it's running rich, come out with the air screw and see how the throttle responds. If you only come out a turn or 2 and it runs good, drop down 1 jet size. My 89 200 is running a 152 MJ 42 PJ and a CGK needle 2nd clip from bottom.

My bike is stock except for the reeds and lid removed. If you have work done to yours, you should be even leaner i believe.