Snowhawk, I think you pin-pointed at least 50% of the problem. Today we installed a new condensor and points (genuine Honda) and were especially careful to gap and time properly. Also went thru petcock and completely cleaned and checked, disassembled the fuel cap and cleaned and replaced gasket, as well as subsituting all the worn out, stripped and boogered up screws. However, did not get charging system working as rectifier still has not arrived. Arghhh!
Ran bike and with all changes ran about the same. Since charging system isn't working, decided to try running bike while on charger. and what do you know, it showed a noticeable improvement in top end. So now it idles great, has a bad sag or burble in mid range and will rev out to some degree while on battery charger. Since the needle mostly controls the midrange, I pulled it out and looked at it under a magnifying glass. It does show some wear and without knowing how worn the nozzle is I'm just going to order them both and replace.
Today I also replaced the brake pedal spring and tightened a few more miscellaneous nuts and bolts. It always amazes me how pieces of machinery can be used until there is so little left functioning properly and yet they somehow continue to function, then when you are working to resurrect, there are layer upon layer of problems. It does keep it interesting and a challenge.
Good luck with whatever bike you decide on, do you ever go to any races? The reason I ask, is that AHRMA has an event in Crooked River called Steel Stampede, missed it this year but am hoping to make it in 2012, maybe I will see you there?
Originally Posted by snowhawk jockey
The slide needle/nozzle in those carbs is also a wearing part. I had an old 70's "barn fresh" xr 80 and the needle had vibrated in the nozzle for sooooo long(decades of changing water on the back 40 and barn yard hot laps) that the needle/nozzle were worn thin allowing much more gas than the motor could use. Replaced the needle and nozzle and it would cleanly rev out again. Another snag with that bike was that the edge of the exhaust valve seat had been eroded and wouldn't allow a good seal resulting in low compression allowing it to fall on its face, when the throttle was opened too quickly.
Great thread, which has me eyeing the classifieds for that canary yellow cl66 type, I passed up so long ago... Might have to pick up that CL175, that keeps turning up on the local craigslist, as a tide me over!