I had some problems with my lightbar as well. OEM bulbs lasted only a few months. Replaced with 55w bulbs (original were 35 w??). These bulbs were obviously hotter and I had problems with the wiring coming in contact with the bulb holder melting the insulation then shorting out and blowing a fuse. After that, I kept some electrician tape & fuses with me wherever I went. I was also about to upgrade to those Xenon bulbs that Brent or Fasteddie sells. I've still got them, waiting in the garage for next 07 TBA.

The toggle switch was a problem as well.

I would recommend that you be real careful in how you leave/lay the wires in the housing. Check to be sure the insulation is intact and not in contact with the bulb or bulb holder.

Blue/White 2007 TBA, Thruxton needles, Unifilter, AI removed, Polaris Bellmouth, Bubs, Nology Coils/wires, Lightbar, Ricor Intiminators, Hagon Nitros, Tall Sissy Bar w/luggage rack, Dart flyscreen & Lowers. 130 Mains, TrueGel Battery MG12-BS.