There was another bloke that did the same (Texasbrit) but I dont think he is still active on here.
I found
this thread on the old boards about it.
We exchanged a few emails about it because I was planning to bring a bike back (until some POS scum stole it!!).
I think as well as getting the heaqdlight changed, he had to get
SVA approval as well. I might be wrong but it is woth reading the DOT site to make sure.
With regard to questions 3 & 4, a look at the
DVLA site should give you all the answers (hopefully).
Dont know about shipping as I didnt get that far - if you are bringing other stuff over, maybe you could ship the bike with that. Do a google search to see what that brings up.
Last point, customs will probably try to get you for import duties - check
here for more info - might be worth an email or two to see if the age of the bike makes a difference to any duties.
Good luck