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On such a simple fork I would just run them as is or swap for something newer.

How melted are the wires? Only takes two wires stuck together to mess with that relay. Also, as far as the starter switch goes do u show power at the bar switch with ignition on? Should show 12v until button is pushed.

Oh, and about that starter switch. You said "painted everything". Did you paint the bars? The start switch grounds through the handle bars. HTH.

It is only tied to the signals, nothing more.

I would start near the headlight relay and see if anything looks like it was modified. If not, it should have power @ relay on red/yellow wire with key on, ground on black wire, white wire has power only when engine running. Blue and black should only be hot when relay is on. (running engine)...

Did you try the kick starter? It sounds dumb but mine does it. Electric start= nothing but a loud back fire out exhaust once and a while. Before it gets flooded I get half a kick (on a warm day) with the old trusty leg and its running.

I am assuming you are using the electric start? Try kicking it once and see if it hits for you then. I am having some trouble with my 1980 xs400 that I have not pin pointed yet and acts like this on electric start. Almost as if the starter is taking to much power away from ignition.

Im in! Could use a set that are bent!

Had it since I was 13, decided it was time to do something with it