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with your permission...back to bike #1.
An idea, but will likely need to wait till riding season to implement.
Get an inexpensive digital voltmeter temporarily mounted, ride and evaluate IF and WHERE in the RPM range, the bike is charging...or not. And to what degree, noting voltage at RPM readings.
It is typical for older RR's to shunt (shedding over voltage) and spike (regaining) at various points of the RPM range.
Otherwise I'm at a loss...as you've apparently eliminated wiring, connectors, RR's, stator, batteries.....et al.
Unless you've overlooked or missed something somewhere.....?
So, actual real use voltage monitoring may be called for next, may reveal something.
Have you actually had the battery load tested at an auto parts house? If internally sulfated to any degree, they become compromised...turn into a big ole' resister within the system. Standing voltage readout is not always the final judgement on battery condition.
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