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How too-small are they? There are "Leak Proof" brand name seals out there that are actually a push fit into the fork leg, versus the press fit style, originally installed. Never had a set, have no idea how they work but they claim they work really well.
Take the master link off, an attach two pieces of wire to the chain to keep it from getting lost. There is a small"O" stamped in the cam sprocket, it points up with the crank at TDC.
Were the valves adjusted before the compression test? A tight valve will make a big difference in compression #s. Popping in the exhaust can point to a carb sync issue. Maybe a good tune up would be in order before tearing everything apart.
If forced to deal a leaky rectifier draining the battery, I would be inclined to replace it. If it's in the condition to drain the battery most likely it's not charging all that well when it's running. A $3 Radio Shack rectifier can solve a lot of problems.
As I recall, the "ch" terminal on back of the main switch is just a convenient way to join the red/white wire from the rectifier to the wire harness that connects to the battery terminal. Another (fused)wire comes back from the battery and connects to the "bat" terminal on the switch. Two separate w...