I was wrong

[mrhtbd]

So much for theory without application in shop. My earlier assumptions about my BMW R100 charging system failure were totally wrong. Well, you know what they say about assumptions! Anyway, I put it on the cycle lift and went through it step-by-step. Removed the front cover, then I removed the rotor, stator and diode board and tested each with an ohm-meter. Oddly though, each tested within factory limits, hmmm??. Anyway you know the saying, "If it ain't broke, don't fix it!" So I reinstalled them all after putting the rotor on a drill press and polished the contact points. When I pulled the battery each (6) cell was over an inch low on fluid. Hmmm, odd for a 4 month old battery. Something was overheating the battery and forcing the fluid out. To be on the safe side I replaced the voltage regulator. Charging system puts out 17 volts but the battery is supposed to be regulated at 13.2. This same thing happened to batteries the past 4 years causing me to purchase and install a new one four times!?! Arghh! Anyway I added distilled water and charged overnight. When trying to start it using a shop battery the starter failed to engage and at times whined and was weak. I removed the starter and bench tested it. Result; weak Bendix drive and solenoid. Great, BMW starters run $450 IF you can get one and now the bike was stuck in the garage on the lift. No problem, called Euro Motoelectric in Colorado for $119 and paid $85 to have it in PA by 10AM Tuesday. Also bought a new battery, because, after adding fluid and charging it to 13.2 volts as indicated by the ohm meter, I did a specific gravity test and every cell failed, therefore the charge wouldn't last. Since the starter relay was also suspect, the next morning my friends and I went on an 85 mile round trip to the only BMW Dealer with-in 100 mile that had one in stock. When we got back, the starter and battery were sitting in the front porch. Very cool!! After installing the new starter, starter relay, air filter and battery, it started up very strong and was ready for a test drive. I drove it 25 miles, had dinner, then another 25 miles to get home with no issues. It needs a distance run though to be sure.