OP I took my toy to the dealer 10 days ago and finally got a part of an answer. Between their electrical man and their computer they came up with either the voltage regulator or the stator. They finally got it started and It is putting out 16.8 volts. That is why my headlight blew up. They said they checked out the stator and the ohms reading is good, so no major short there but they cannot rule it out entirely. That leaves me the regulator. everything else seems to check out okay. So I am going to buy a regulator for my machine.
That high of voltage would destroy a a battery. Mine was swelled up about 3/4 in on all four sides. I couldn't tell until I took it out. It still carries 12.2 volts. I will buy a new one for it after the regulator is replaced. Things like this should not happen to a machine that is only 3 years old and 4600 miles on it. I think it was wrecked before I got it. After taking off most of the plastic testing things I found several places where bolts were missing or washers had been moved. Maybe it is me but I'm getting uncomfortable riding it very far. I do need the workout but not in the winter when you drive 5-6 miles to go get the mail on the Snake River every Wednesday. I'll let you know about the regulator when I get one and install it.

 

I mentioned overcharging in my first post when you said the battery case had swelled out. Yes replace the regulator and battery as overcharging from the regulator just overheats batteries and causes cases to expand if left long enough.This should solve at least one problem,if not all of them including blowing fuses.