Can you trouble shoot your bike and still stay close to home? Try riding around a loop close to you house for a while, let the bike warm up, and re-check everything. Pay close attention to the condition of the wires that melted before, check your resistances, and take your time. When you hit the gas you are putting a load on the battery and reducing the voltage. That is pretty normal. The stator output should go up and your lights should brighten up a little bit. If the book says you are supposed to be at 0.4 Ohms max, and you are at 0.6 Ohms, that is 30% high. Can you go somewhere local with your voltmeter and check another new unit for comparison to the one you installed? Just a few thoughts...