I have a 1991 Accord and it has worked fine for years and years with normal maintenance being done. Recently, I had a bout with a dead alternator and put it to age of the alternator. My system has a Hifonics ZX600.4 amp going to an Infinity 6.5" Component set. After I replaced the alternator, the new one died really quickly. It was an Ultima alternator from AutoZone and it was new. I got another one and am now having a random intermittent battery light.

I checked the fuses and they are all good. The issue doesn't occur when the headlights are on (high power mode) I am thinking of replacing the ground wire and adding a 0 gauge from the alternator positive direct to my battery, along with replacing the battery chassis ground with some nice 0 gauge.

Besides that, does anybody have any suggestions?

 

You might want to inspect the serpentine belt and check the belt tension. A slipping/worn belt plus the extra load on the alternator could be causing your problem.

 

New belt, tension is fine. Interesting that the light never comes on when the headlights are on.

 

Drawing a blank on the gens...sad getting old.

Take a marker and draw a line from the inner part of the crank pulley to the outer part. After a few drives, check the mark...is it still lined up? There is a rubber ring on the crank pulley and if it is slipping.....well the alt isn't spinning enough for proper voltage.

I am not a radio person, so the set up might mean an issue.....