How was the generator tested? If it was tested for voltage, that will be normal even if it has a bad internal diode. One bad diode out of the six will reduce the generator's maximum output current to exactly one third of its rating. That's not enough to run the entire electrical system under all conditions. You need to have the charging system professionally load-tested to identify a bad diode. Besides the output current that will be too low, "ripple" will be very high.
The brushes in the generator can be worn too and making intermittent contact. They are bolted to the back-side of the voltage regulator and can be replaced separately without replacing the entire generator.
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Thursday, March 21st, 2013 AT 11:46 PM