Well after all the phone calls and e-mails saying the the DS headlight switch I purhcased would be able to handle my new 100W headlight, the hi/low beam switch smoked and melted. So I spoke with the company that sold me the switch, they contacted K&S who is the manufacturer. K&S e-mailed me stated the switch will work just fine with that much current (around 8amps). I then called Baja Designs, and they said their switch is used all the time with the same kind of 100W setup (though their assembly is wired a bit differently, but looks to use the exact same hi/low switch). I even called the guy at fourstrokesonly.com who sells a similar, if not the exact same unit. He said it should work just fine. So whats up??? I know its not the wiring. I have 2 wires coming from the stator, then connected to a 200W AC regulator, and one wire from the regulator goes to the headlight switch main power, the other goes to the headlight ground, then the hi/low wires from the switch go to the headlight. And it all worked perfectly. The wiring all held up just fine. No melted insulation or anything like that. It was the actual switch inside the DS assembly that completley melted. It got so hot that it melted the solder right off the low beam wire (after completely melting the switch) and the wire fell off causing the smoke to stop and the headlight to turn off. There was even a nice solder blob on my handlebar when I took the switch off. At least the rest of the assembly works, and the switch is removable. So I'll just plug the hole, and run a seperate switch for hi/low beams that I know will handle the power. Anyway, don't use a K&S DS switch assembly and run a 90/100W headlight through it!!!