Can anyone suggest the best thing to do with the awful headlight the Thunder cat has, except never take it out when it is dark.

I use to have a Thundercat and can't remember it being a major ssue and I used it all year round .. so often in the dark.

Have you checked that your bulb isn't knacked and gone all funny.

If I remember the cat had a Glass light lens so you could try upgrading the bulb (don't do it if it's plastic though as it's likely to melt the lens).

Another problem could be the wiring, if the wiring is poor, too much resistance will lower the feed power. Try putting a live feed to it and see if it helps, if it does, then mount a decent relay on to the bike and move the current feed of the light to swithcing feed the relay instead and then put a feed direct from the bike through the relay and to the light. (make sure you wire up the relay terminals correctly though. (The realy will also need to be earthed).

The problem is probably poor contacts on the switch and poor earth. All need cleaning.

Try upgrading the bulb from a 60/55w to a 100/80w. Both come in H4 fitting so will fit the Cat and I've heard there is a definite improvement.

I changed my headlight for a UK spec recently, and put a 50% improvement bulb in from Halfords (can't remember exact name!)

It has made it a lot better, and on high beam, I can see well at night and in poor light

Try upgrading the bulb from a 60/55w to a 100/80w. Both come in H4 fitting so will fit the Cat and I've heard there is a definite improvement.

Dont try this.

The cabling and switch gear are not sized for this power consumption

Dont try this.

The cabling and switch gear are not sized for this power consumption

Fair play. Not done it myself, just going on what I've heard.