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It kinda sounds to me like the only thing you HAVENT TRIED is to by pass jump around the Cutout Relay in case the relay is bad n it never closes as it should once the gennys voltage is greater then the batterys !!!!! !!! When you jump flashed a wire from the relays BAT terminal over to its Gen terminal (Polarized) did you get a spark????? ????? You should have ifffff f the relays BAT terminal is always hot voltage as it should be since it wires to the ammeter, is the relays BAT terminal ALWAYS HOT it MUST BE or else the wires bad from the ammeter down to it... I would first insure the BAT terminal on the relay is hot,,,,, ,,next insure the genny and relay BOTH are well grounded (run a jumper from grounded battery post direct to genny n relay to make sure n try it),,,,, ,,,,next temporarily dead ground the gennys Field post to the gennys case,,,,, ,,,then flash polarize by momentarily jumping a hot wire from the relays BAT terminal over to its GEN terminal or direct to the gennys ARM post (need to get a spark),,,,, ,,,,then when running see if she charges if you dead ground the gennys field post????? ??? if so but NOT otherwise, its either an open wire from the gennys field post up to the light switch,,,,, ,,,,,orrrrr rrrrr the switch is bad,,,,, ,,,,or the switch dont have a good ground to the dash. If it still does NOT charge even with the field dead grounded (and genny n relay both are well grounded and BAT side of relay is hot), leave it grounded and when running test the relay by by pass jumping around it closed (hook BAT to GEN),,,,, ,if it charges then, the relay is bad n not closing as it should once the gennys voltage rises. If it still fails to charge even with the relay by pass closed and the field dead grounded assuming the BAT terminal is hot n the gennys is grounded, Id say the genny is bad. From your post my best guesses are the genny n relay arent well grounded or the relay is bad n never closes. John T
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