I found 50W halogen headlights for a 03' cat 500i today. I had two of them go bad because the light housings are not totally sealed. The stockers are 27W.

 

Sorry, they are part #885 from O'Reilly auto parts. The stock ones are #880. The only difference is 50W versus 27W.

 

Sorry, they are part #885 from O'Reilly auto parts. The stock ones are #880. The only difference is 50W versus 27W.

 

You might want to check the wiring for heat buildup after you get them installed. Thats almost doubling the wattage going through the wires that might not be up to the task. If anything you might put a relay to keep the load off the factory wiring.

 

Aren't the lights already run through a relay? Should be. As for power consumption, I think the stock wiring is up to the task, but are the lenses? Lotsa heat off a 50W bulb. Seen a 500i the other day with 2[img]i/expressions/face-icon-small-shocked.gif[/img] 100W KC off road lights from a truck? Can't miss him coming, don't know how long his electrical system is going to last though. More light, more power, more diggin'!

 

I've run 4 55W lights before on an old Big Bear. I've seen several people run 2 110W off road lights on different 4 wheelers. I've never seen anyone or had any trouble myself with the wiring. I'm only running 2 of the 50W lights in place of the high beam 27W's. The lows are still the factory bulbs. I'm also running a spotlight from Wal-mart on the front rack. It's in the ATV section, comes with a pretty cool mount for about $30. I originally had it mounted on the handlebars and it worked great. It almost looked stock. I had to move it to the front rack because of the snorkel.

 

Speaking of lights, my lights are aimed really high, looking up at the trees both on high and low beam, is there any adjustment there?

 

They are really easy to adjust. Remove the front grill. There are only 2 screws in it (star wrench) use the tool in the factory tool kit. Look to the left and right. There is a single nut. Loosen the nut, adjust, and tighten down. If you back the nut off all the way you can take the lights off for cleaning or whatever. Hope this helps. It really is easy.