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It really sounds to me like the battery is bad at this time. It can act like a capacitor and charge to the highest peak voltage applied, which will be an AC component riding a rectified DC output. If it were mine, I would add a choke filter (inductor) after the rectifier to lower the AC component, and add battery capacity at the same time. Just make sure the choke is rated for the DC currents involved. Same thing for the Zener, it might be breaking down under load. Just some thoughts.
Another trick that can work is wiring a side light bulb so that it's on while charging, then just stash it under the seat or something. Works on my Honda Express that used to blow bulbs on a regular basis.
ok , i located a new battery ,,,£8.50 ,, and local , all the internet sites wanted £7 + about £5 postage ,, so its cheaper local.
i suspect the voltmeter as well ,, so am gonna build this little kit http://www.canakit.com/Default.asp?C...tems/CK005.asp and with a mod to a resistor , i can adjust the min/max ,this one is in the USA ,,there is one at www.cpc.co.uk , and thoughts are goint thru my mind to use a tri-color led (for neatness) ,,,
let u know tommorrow
alan