I don't know if this applies, but my alternator has a big pulley on it to slow it down so it doesn't burn up running 6000+ rpms all day. The down side is, it won't charge while under 3000 rpm or so.

Also, I chased a bad wire for 2 years on my car. When I'd hit the wire with a probe from a meter it would flex the wire and would show good connection but when I pulled the probe off, the wire would flex back into a non-connective way.

Good luck.