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Have you measured output with a quality amp clamp? I have cycled through 4 current meters and none of them are accurate. All read lower than actual. What happens with the engine when you max out at 60%? Does it bog down and throw black smoke? Does the overload fault trip?

Sounds like you found a good one! That fuse is a modification from the original design, commonly referred to as the "quad-fuse". There is a winding in the generator head that provides medium voltage AC power to the voltage regulator. That AC power is rectified through a diode bridge in the...