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Glad to see you made progress. See post #6 above by @Digger556 about the "hunting" behavior, and adjust the governor per the the TM. All the best, 2PbFeet

Using a dial gauge can be a bit fiddly until you get the hang of it, but if your cylinder is within .005mm (0.0002") that's great. The new rings aren't going to hurt. I didn't see anything in the bearings of concern to me, but it is your generator. Just offset the three rings correctly, and I...

+1 on the Molex adapter cable. FWIW: I'm not perfect, so like to have an Molex extractor/ejector tool handy. e.g. https://www.amazon.com/JRready-ST5265-Extractor-Connectors-Insertion/dp/B0C4P1FBHY All the best, 2PbFeet

Yes, I think that bad ring alignment would lower compression, causing lower HP, causing the governor to call for more fuel, overfueling, smoke in the exhaust and excess soot in the oil. I have the hope that the black section isn't actually worn, it just has carbon deposits on it that could be...

Ok, not a ring expert here, so I will pass on whether one being stuck is enough. However, I was taught always to have the gaps in the compression rings 180 degrees apart. Having both gaps aligned might be more than enough (I think) to explain your issue. The oil scraper ring should be +/- 90...

If you didn't have an issue, I might give it a miss, but yes to my eye, that is a sign of an issue. Do you have access to a dial bore micrometer (internal micrometer)? I'd be curious how deep that patch is. If it turns out to be necessary, one can get oversize pistons and rings for this engine...

I do not understand the rust. That area shouldn't get water. The fact it did makes me wonder if water ever got into the cylinder, and caused ring damage. The timing looks ok to me, and that brings me to... You have been chasing so many gremlins (and have fixed so many with not much change)...

In my experience these engines very rarely need timing adjustment. I have never done it. The procedure is in the Yanmar service manual. https://discount-equipment.com/library_files/21623.pdf Bear in mind that injection starts about 13 degrees BTDC in this engine; All the best, 2PbFeet

From the armchair here, that VR doesn't look that bad, but I guess it depends on one's tolerance for repairs. The newer voltage regulators do have a number of advantages. All the best, 2PbFeet

FWIW: I used a few 5/8" SS 10-32s in places where there are overlapping panels. Might not be 100% by the manual, but mine came with a few there to begin with, and the extra few threads certainly helped me with some of the ones that don't have great access. All the best, 2PbFeet

In a pure WAG, I would use insulated standoffs. I suspect that the originals were on standoffs for two reasons; one to reduce heat load into the support, and two in case of resistor failure, to keep them from shorting to the chassis. It is the second thought item that would make me want to keep...

🤣 love the indicator test video! Congratulations on getting your set into hurricane readiness! All the best, 2PbFeet

Not in my experience. It seems as if your engine is being overfueled. If it were me, I would go back to try fueling the high pressure pump directly again and see if that improves your load and smoke. If it doesn't, I am starting to wonder if pulling the engine to check the camshaft timing and...

No, I would describe that as not normal. However, I am not sure that any of us know how much carbon was already inside your muffler which does I think make it a bit difficult to interpret. How does the engine run without the muffler? (E.g. Smoke onset at what load?) After ten hours of loading...

I think that is the terminal eye for a what @CallMeColt called out. It looks like a missing ground for one of your EMI suppressors. (GND to neutral?) You might be able to scrape a little of the compound out of the way and resolder it. By the looks of it, it sheared when some one was really...

Yes, it was the clean exhaust wrap, the spotlessly clean air cooling fins, clean fans, to name a couple, and that was despite the sand and gravel inside. It was also that none of the engine parts seemed to have been exposed to much heat either, as your gaskets came off very cleanly. That...

Ok, if the bulb itself, per @peapvp, is a 28VAC bulb, then these should work; https://www.mcmaster.com/products/midget-flanged-base-light-bulbs/bulb-base-type~bottom-flanged/ Clear, red, green. Not including the cap/outer cap. All the best, 2PbFeet

The 12mm is very common as it is lost 1/2". These come with a better water resistance; https://www.amazon.com/Indicator-Lights-Waterproof-Stainless-110V-120V/dp/B0CPBMYDSG Always happy to help, and I understand the desire to keep things stock. All the best, 2PbFeet

I can't seem to find a drop in better than what you have. FWIW: There are 120V waterproof LEDs available, but they would look different. E.g. these, 8mm 50 lumens https://www.amazon.com/Gebildet-110V-220V-Indicator-Waterproof-Signal/dp/B08LDCQ7LL or these 6mm...

Can you measure the OD on the bulb barrel, and the flange, and the overall height of the bulb (Guesstimate inside your new housings)? All the best, 2PbFeet EDIT: removed incorrect info.