Update:

Pulled all linkages, cleaned, re-oiled (triflow is absolutely the nuts as far as lube goes) and reassembled with the linkages snug but not too tight. Replaced the 9202 on collective, (talked to a bunch of people and the consensus is that 90oz/in is a good minimum for torque on a 60 sized collective system, the 9202 only had 72oz/in). Cycled the batt, and viola!!! Suddenly the batts are OK. Once I realized I had the engine too lean and riched it up a full half turn to begin tuning in again, I could actually hover and fly it around.


Morals of the story

Use a servo that has enough torque for the application.
Make sure all linkages are smooth even if the heli has been flown and especially if it has been sitting around for a while.
Use something to watch voltage (and implicit current) activity on the electrical system in flight, too much of a drop on a fresh new pack indicates a problem with one of the components, replace one by one until it works.