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Ed - couple of guys on the UK forum had a similar problem - we went around the houses checking voltages at various points, grounds etc. Turned out the headlamps were just not wired right, There is apparently (and I haven't got it straight in my mind yet) a way to make them work wired up wrong (at the bulb connector), but only dimly. Another symptom of this is that the main beam idiot light glows dimly all the time.
When they got the wiring A1 their lights were significantly improved. Probably worth checking out as it's a cheap fix!
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Wilf
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