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Take some wd40 and spray it all over the switch where all the wires connect inside the distribution box. Then lightly tape on the switch, while trying to turn the switch, it will eventually free. When it is free, rotate it several dozen times and see if that helps your situation.
If you look at the back of the distribution box (Where the lugs are) you will see 4 wiring harnesses in the back. The smallest with 2 wires should be the exciter wires going to the generator head. You need to take the cover off the back of the generator head and you'll be able to see the exciter.
Go back to the VR. You had 70 volts before turning the pots on the VR, after turning them you have nothing. Even with the spark you saw, I still say its the VR.
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