what bulbs are you using? I have been just getting some at the auto store but they burn out or can not take the vibrations and burn out after 6 months or so..

 

I've been running a Sylvania Silverstar auto bulb in my KLR - has held up well so far (about 8 months) and I run quite a bit offroad too...

http://www.autothing.com/Products/Au...t-h-Syl-SS.htm

 

I run standard H4 ( I think that's the number) bulbs in mine. I used an excessive amout of dielectric grease this helps absorb some of the shock the bulb gets from being in the socket. I have heard that others use that grease that comes with new sparkplug wires for cars. I did this when I upgraded the bulbs after I bought it from first owner back in april. Other than that, the bulbs were original.

Have a blast!

 

My 1990 used the Honda priority, 45/45 bulbs, but I switched to regular H4's by cutting off the 4 and 8 o'clock tabs. The spring clip holds them securely in the housing. I have been using Candlepower 55/60 bulbs and like them.

 

The fix for mounting Sylvania Sliverstar 9003 St bulbs or any other bulb is quite simple.

Tools needed: pliers, wire coat hanger

(1) Flaten the tab at 12 o-clock. (it will widen it some as the stock part is wider)

(2) Flaten the two **** at 6 o-clock. (important)

(3) Cut a small piece of wire coat hanger to the length of about the diameter of the round disk of the bulb.

(4) With the piece of wire placed behine the round disk at 6 o-clock, bend the two tabs at 4 and 7 o-clock back tward the electrical conectors and squeeze them down locking the wire in place.

(5) Install the bulb as if it were factory part.

 

I go to a local auto electrical shop and buy H4 100/80 bulbs. Cheap to buy and no problems with any bikes or cars i've owned.