If you rebuilt the carb have you moved the air screw position? If so (or if you can't find any airleaks etc) turn it in by 1/2 turn to see if that helps (should richen up idle/starting) if not turn in another 1/2 turn if that doesn't help something's up...
If the bikes are too lean at idle they will normally rev up/surge when they are very hot - any sign of this? - usually after a run on the road or widish throttle opening for a while then stopping or going slow (i.e. bike is on the idle circuit)
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'05 Gas Gas 300
'97 Aprilia Pegaso 650
'99 KTM 200
'95 ish XR630 (died many times in Oz)
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