Ah, I never used lighting levels above 100% (and it doesn't look very good as far as I know). Will test it soon.
Regarding your other question: Yeah, I was always wondering why Illustrator does that*, and after going through some forums it seems that there's no way around that. But you can just copy your character into a newly opened File with the right size and "save for web and devices" - which is, I think, copying the entire artboard. Just make sure that the artboard has the right size.
* it's not always the bottom edge.. it can be every edge.
Regarding your other question: Yeah, I was always wondering why Illustrator does that*, and after going through some forums it seems that there's no way around that. But you can just copy your character into a newly opened File with the right size and "save for web and devices" - which is, I think, copying the entire artboard. Just make sure that the artboard has the right size.
* it's not always the bottom edge.. it can be every edge.