it sounds like you have experience with this, so I'll post this for anyone else who hasnt experienced this before, because it WILL happen!!!
well the regulator gets hot because electricity that is wasted turns into heat, if it gets too hot the regulator will fail, heat does funky things to electronics.
regs can either undercharge.. or over charge, either one will leave you stranded eventually. usually the first warning sign is a dim headlight. when the reg is cold, youll have no symptoms, unless its really really bad. it isnt until theyre warm do you find out that there's a problem. they can go undiagnosed for a long time. usually on your first big trip, or interstate run.
it likely lowered the resistance in the reg and sent too much voltage to your batt, however, you should have smelled the sulfur burning? unless its been happening slowly over time and it was unoticeable. you can ease off some of the voltage by keeping it in 5th gear, with your brights on, blowing your horn the entire time that you ride.
you can buy a battery from walmart and replace it every time it messes up, when my reg was going out on my magna i rode it until the battery broke into pieces on the inside. 400 miles from home.. what choice did i have?? i kept returning them LOL.
undercharging would not cause your battery to boil the sulfur out... how old is the battery?
did it have any "caps" popped out? maybe the mod monkey said it was time for a batt upgrade.
reasons theyre hard to diagnose
- cold weather keeps the reg cooler, so it wont overheat and fail
-short rides dont allow enough time for the reg to overheat
- the battery will recharge itself as it sits from the chemical reaction of the sulfuric acid.
- it takes a long time for the battery to be damaged.
- if undercharging, your bike will use more power than the system is charging, but as you finish your ride and it sits for a while, the battery will recharge itself. you usually dont get a "surprise stranding" until the battery is really bad.
- its a silent killer, noone inspects their battery but supposedly dannymax, thats it.
the main symptom for overcharging and undercharging is the dim headlight, youll likely never notice, because during the day you cant see your headlight, and at night its cooler outside, and youll most likely be taking a short ride anyway.
you will be stranded, and it will suck.
after a long ride on a hot day, when you rev your bike up, the headlight should get brighter and then dim at idle, no reg is perfect. but it shouldnt be tooooooooo drastic. if you suspect foul play, get it checked out