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One word of caution, the MEK will likely dissolve more than the potting compound, the plastic sleeves around electrolytic capacitors that have the polarity and component values are one example, so I pay close attention as it dissolves of any component values, part number etc. Of course this is...

If it is a hard resin, I use MEK to dissolve potted electronics, the regulator I have seemed to be somewhat pliable, I have not tried to dissolve it yet. I was thinking it may be silicone based but if that were the case the alcohol you are using would have no effect, so I would think the MEK...

Yes that is how it should be connected

Absolutely move all acc. loads to the batteries, I also would while running at med idle test the battery voltage with the AC on and off, make sure the alternator is balancing the load (same voltage on both batteries) or you could kill another set of batteries.

The above troubleshooting guide is very good, forget trying to get any current measurements, voltage is all you need, basically if you see battery voltage at the output terminal and at the exciter terminal and the voltage running is not around 28V it is probably an alternator/regulator issue...