Honestagawd, I think you got a bad VR and that's not somethin' you can get around, so you ain't been beat. Without a lot of bench test equipment that most folks don't have anyway, You pretty much had to slog through all of that just to make that determination without throwin' away good parts. But they're a strange beast. If you're old enough to remember when they were common on cars, their failure was not an uncommmon thing.
First one I got for my SuperC when I rebuilt it in '01 was just plain bad. Next one hung in for three years before it bit the shed. Latest one is hangin' right in there, goin' on five years. When the VR is working right and the battery has a good charge, I normally see only 6 or 7 amps charge for a short while when running at half throttle or above after a start. Once recovered from the start, it will move between zero and about 2 amps to the + side while running and sorking. If I leave it sit at an idle after workin, it will show a slight discharge, but picks right back up to the 0 - +2 action when revved back up to move it. It's not near so dramatic as the swing of the needle on the ammeter on a cutout relay with the manual control of the charging circuit through the 4-position switch. On that I can see 12 amps or more on high charge after a start, and it runs at 2-3 on low after that.
So I'd agree. Chuck the VR, but never throw a good hammer away. Yeu can take If somebody local can direct you to a good motor/generator/alternator shop, it won't take them anytime to bench test your generator. They can also ttune up that third brush if it can be done. That might also be a good place to get your next VR, and have them test it. If they've got any kind of good reputation at all, they'll deliver back parts that work.
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