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Thanks. Good to know. So far, apart from the rusty, broken springs in the kill switch, everything is recoverable. I have ordered some 3mm OD x 10mm long springs off eBay. I actually think 1/8" OD x 3/8" long would be a better choice but I can't find any. Given that all the springs do is push...

After a few days away from the bike, a bit more progress today. Stripped the right side switch gear this morning and as expected it was found crusty as a crusty thing. Both the kill switch and the starter button are salvageable though. Had to order a couple of small springs for the kill switch...

Stripped the kill switch and starter button out of the right side switchgear this morning. Didn't have far to look to see problems. Obvious that the switchgear has been full of water at some time in the last 47 years. Kill switch issues are one broken contact spring, one very rusty contact...

Yes, I tested it with a blind bolt. It would move fluid but not pressurise. It was sent back to the seller and a new replacement was sent to me. The replacement works fine. I suspect from what was happening is that the seals on the piston were installed backwards. But that's speculation on my part.

Thank you @5twins. That's absolutely stunning information. I have no time for the next few days but I'm going to have a crack at this. May I ask, do you know if I can firm up the centre detent "click" in the kill switch? At the moment it's so weak I think a large bump in the road would leave me...

Oh, great find. Much appreciated.

The contact cleaner route was tried a few weeks ago in preparation for a first start. But on pressing the start button it's stuck in the closed position. So the next step is now on the agenda. I have no motorcycle time now for a few days so I'll not decide what to do just yet. But at least the...

As far as I'm aware, nothing Yambits sell is Yamaha and you're right about quality. I have looked around and found the same pattern switch for £33 now if I need it. Yes, running a separate fuse and relay to the ignition is 100% on my radar. But first I need to shake the bugs out of what I have...

That's useful to hear thanks. I did wonder about fitting a seperate kill switch. But the big issue is more the sticky start button really. I 100% need to fix this before thinking about the kill switch. Then, I have to track down for certain why there's very weak to no spark. Could be the kill...

Thank you. That's most useful. Can you remember how the kill switch detent works? I need to tighten up the "click" on it. As it is I think a bump in the road could cause me to lose ignition. So it needs fixing as well as cleaning.

Well, yesterday afternoon I got to cranking the motor on my 650 for the first time in my ownership, plugs were out to test for sparks. Good news and bad news. The starter cranks really well with the plugs out. But two problems have arisen. Firstly the start button has stuck closed so I have to...

Sorted it this morning. Link - https://www.xs650.com/threads/turn-signal-issue.66381/post-839620

A productive morning again. Did the painting I prepared yesterday as it's a nice sunny day and the paint will be fully dry by this time tomorrow. The battery is now on charge again this morning so I fitted a new flasher unit. One that works independent of what type of bulbs are fitted. It's...

OK, I've fixed my turn signal issue while the battery was charging on my bike. How to wire a CF14 load independent flasher relay to an XS650. Caveat - I am not an electrician. This works for me, there's probably other ways that work too. Follow my instructions at your own risk. I wanted to...

I have a similar issue by the sound of it. The indicator lights come on but they don't flash. The battery I installed is new but wasn't fully charged. I'll be charging it today and I think that will fix the non flashing problem.

Same as the first picture you posted, blue. Needs repainting though.

I found 1/4" drive sockets very useful to access the smaller head fasteners. They fit in the limited space quite comfortably. I tightened the smaller fasteners by feel. Used a normal 1/2" drive torque wrench on the eight bigger fasteners, of course.

Thanks for that. A timely comment as I'm probably going to fit this tomorrow. (Retired PEng, Mechanical here, I'm listening!)

Thanks, it's an unknown quantity presently. I changed the 47 year old rectifier and the regulator largely on the influence of what I read here. The regulator is an automotive type B three wire regulator originally used on Peugeot, Lada and other vehicles back in the day. I am parking the testing...

That's my thinking too. I'm charging the battery now and then I'll check the brown switched live and the brushes again. At the present I'm tempted to finish off testing the other electrics and see if I can get it to start. The solid state voltage regulator is a complete unknown to me so I have...