1. Dead ground the gen field post. (Do I remove the wire from gen field to relay field first?)
NO thats not necessary, just run a temporary jumper from FLD on Genny to a good clean case/frame ground. If the VR is working correctly its supplying a regulated/intermittent/chopped ground to the gennys FLD post anyway. When you dead ground the gennys FLD that forces it into high max charge and it no longer relies on the VR
2. Jump a wire from Relay's BAT term to its GEN terminal. (Do I remove the existing bat and gen wires first?)
Again NO thats NOT necessary, just temporarily jump BAT to GEN/ARM on the VR as that simulates what the cutout relay (between BAT and GEN/ARM) does anyway when the gennys voltage exceds battery voltage.
NOTE with the gennys FLD dead grounded and the cutout relay by pass jumped across, THE VR IS OUT OF THE EQUATION so if still no charge the genny is bad unless theres another wiring problem??
NOTE The wire down from the load (NOT battery/starter) side of the ammeter that wires to BAT on the VR MUST ALWAYS BE HOT WITH VOLTAGE as thats how the gennys output gets to the battery to charge it. If its not getting to the battery (via ammater if it has a good one) even a perfect genny cant charge the battery.
NOTE Put a voltmeter on the battery and sitting it should read 6.3 or 12.6 but once running at fast RPM if the charging system works battery voltage should rise (6.5 to 7 on 6 volt or 13 to 14 on 12)
NOTE if its a 3 brush genny some are adjustable to increase the charge rate, maybe you have a 3 brush adjustable type and its set for low charge?????
NOTE on some VR's they dont work exactly right if the metal cover is removed.
The above and my Troubleshooting Procedure is about all I can do over the net to help, maybe Jim or Bob M or Mayor Bob can add more, Im runnin outa smarts here and that dont take long either for me
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