Join Date: Apr 2002
Location: Dandridge (Near Knoxville), TN, USA
I ran 70 watt low for about a year, 30,000 miles, with no problems at all. I finally decided that was not enough so put in HID low beam. I ran the 85 watt high beam for the life of the bike, 4 years, 110,000 miles. Never had any problems with connections or housing overheating.
One of the keys is to use dielectric grease on the terminals. That keeps the terminals from corroding, making the connection worse and worse until the resistance gets high enough to cause heating.
The heating you saw was not from the bulb, but from higher than normal resistance in the connections. They either were not tight enough, or had started to oxidize, causing a resistance connection.
100 Watt bulbs however do over heat the headlight assembly, causing plasticizer outgassing, which clouds the reflector and lens, almost impossible to clean if it does.
I don't want to achieve immortality through my work...I want to achieve it through not dying.
EX: '01 Black LT, BAT BYKE (Totaled at 110,000 miles)
IBA SS, BB, BBG, 10/10ths.
No bike now, but maybe in the future.