OEM Side cover gaskets don't survive re-use very well. They have some sealant on one side and stick to the cover or engine case. Easily torn. Always order a new one and have a spare in stock for both sides.
As I said on the other forum, if you need electrical info, let me know.
Your problem could be your side stand switch if you have one. Where are you located. Euro bikes don't have the side stand switch but USA models do have it and other country bikes may have it. Bypass it at the bullet connectors. If you don't have a side stand switch or it is already bypassed try disconnecting the black/white kill wire and see if anything changes.
Since this bike uses a CDI and charge coils in the stator, the battery is not needed to run so you can dismiss that as a problem. It is sounding more like a CDI going bad. Check all your connections from the stator and at the cdi /coil area.
Steve
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'84 XT600 is now bored to 2nd oversize and new OEM pistons and rings installed. No more smoking.
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