Be sure the Voltage Regulator has a good ground (usualy to the gennys case/frame) before you toss it as it cant work correct otherwise. What you describe indicates its internal Cutout Relay is bad (externally jumping BAT to GEN fixes that) or needs adjusted, but if that makes her charge well that would indicate its ground is okay, but still wouldnt hurt to test it by grounding the VR to the genny using a lil jumper. Also insure the VR is compatible with your ground (Pos or Neg).
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