It all starts right here.
Sort of - the generator in the photo is the original AutoLite, which I converted to 12V with a Podtronics voltage regulator (hidden in the original "box"). This setup works well, but it gets so hot that the wax on the field coils melts and drips out on top of the battery box. A CycleElectric generator has eliminated that issue, and been completely trouble free for the last 17K miles.You showed now tell. Did you upgrade the generator?