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[grandpa]

I had same issue last year (melted headlight)
It was replaced under warranty... But with more than 3 month delay... Zero as very suspicious and took lot of time to accept warranty replacement.
I had stock light but replaced now with led. My dealer installed led with fan... So now each time i start the bike, there is a little noise and some vibrations i can feel in my hands

[GilTitan06]

Hello, For information I replaced the bulb H4 by a bi led. Result better lighting. Less consumption and a lighthouse that stays cold. Good road. Gil

[dhln]

I also changed my H4 to 25W LED by Nighteye (model A315), resulting in a cooler housing and better visibility.
Another hint which I got from my Zero dealer:

You can "switch off" the front light completely by placing the high/normal beam switch between "high" and "normal".
There is a tiny range in the middle where the light stays off, the dealer told me that they are using this for exhibitions to prevent overheating.

BR Dennis