headlight fuse blows!!

it didn't do it at first

but now id di it again!

it is burning the head lamp fuses,

even burned the lid!!

my question is:
where should i start trouble shooting?

 

The head light circuit schematic should be a great source of information. I would start at the headlight connector and physically trace its path back through the headlight switch, relay and fuse panel. It is fairly straight forward and shouldn't necessitate too much parts pulling (fuel tank and headlight bucket should do the trick). Look for a pinched wire or chaffing. Another thought, have you made any modifications to the machine recently? Possible problem point there. Good luck amigo!

 

hmm no i havent done anything lately

luckily its been working fine!

i did change a turn signal bulb

which don,t blink, because of lower amperage.

but i dont think it would affect the headlamp right?

 

Correct. I've not looked at your schematic as of yet so I really cannot suggest any external sources of trouble for your headlight circuit. I'll try (mind you this is as time permits, and my daughter isn't giving up my attentions very easily) to get back too you shortly.

 

I would also check your voltage at the battery.
If it's low the headlight will draw more amps.
A poor connection (resistor) will cause this as well.
This could also explain your blinker woes.

Nachoman

 

make sure you arent somehow leaving the high/low beam switch in between high and low. my head light fuse got blown a couple of times, and it was because of me somehow bumping that switch just between the two, thus leaving both high and low filaments on. by drawing too much current, due too a lowered resistance (both filaments in parallel) it drew more then 10 amps blowing the fuse.

 

well it seem the fuse wasnt blown this time,

this time the fuse holder broke!!

which means i'll finnally have to

put a new fuse box. :idea:

but the one i orfered hasn't arrived yet!!

so maybe ill just put a fuse for the lights

separate from the rest, simce it's been blowing!

 

I'm ready to order a new fuse box myself. The connectors that hold the bus fuse in place snapped on me the other day while changing out the fuses. I've got them rigged with electricians tape and paperclips at the moment.

Looking into modifying it so it will hold the flat automotive fuses as apposed to the cylindrical ones.

 

Just be sure to find some way to seal the box against the elements or you will have to visit this problem all over again in a couple of years. I'm still trying to get the time to build my own. More when that happens...