"I've been working on the sled lately, and i don't know if it's too hot, or what the deal is, but every once in a while it is just doggy. like running on one cylinder almost. I by-passed the kill switch, and tried plugs, tuning on the carbs, and i'm stumped."
As I recall, there is a situation where the kill switch under the throttle lever can go bad, and bypassing the switch doesn't do any good, because the switch is still in the circuit. If you've got a wiring diagram, study it close and I think you'll find what I'm talking about. What happens is the engine won't quit, but it loses just enough contact through the switch to cause a misfire.
"maybe the exhaust is the problem. i know it's not plugged, but it leaks quite a bit when i rap on it. Thats another reason i want some twin pipes."
Where is it leaking? Are the springs stretched out on the flex joint? It's your money if you want pipes, But there is a lot more potential in what you've got there. If you are really bent on buying pipes, try to locate a set of HPE pipes for your sled. I remember hearing at the time that they worked pretty good.
"Also, what rpm should i clutch it to?" It was 7200 on the tach on my sled.
"Is there any way i can get more compression out of it? I have several spare heads and i work at a machine shop. How much should i take off?"
The critical thing here is ending up with the proper squish band clearance. Right now I can't think of what that number is. .060" sticks in my head, but I won't swear to it. Generally, you can get away with .015" to .020" and be OK. Although I'd run at least super unleaded gas if I milled anything off.
"I will geep working on it to try and get it straightened out, but now that i think last season i couldn't get more than 75 or 80 out of it, on a hardpacked gravel road..."
Try this again on snow and see if it goes any faster!
That Duster is killing you here. Ash-can that thing!
"I have also noticed the clutch seems to have a wobble like it isn't running perfectly true.. and i need to check the alighment or offset."
I repeat...ash-can the Duster! The offset measurement is probably different with a Comet than with a Hex. I remember the center-to-center is 10.2" I'd recommend calling HPE (High Performance Engineering) about the clutch alignment. I think Larry Coltom is still there. I'd ask for him when I called. I'm telling ya, the guy's good, and he'd be right at home on your old Tiger.
PS: Larry might be able to help you finding a hex clutch.
Stay tuned for more information!