High Beam Keeps Popping Fuse

I have a XJ550 Seca and I re did all the wiring on the bike with the minimum wiring diagram.

Everything on the bike works perfect except for the headlight. I replaced the stock light with a LED bulb. (picture below)


All the handlebar controls are different as well and I'm using a toggle switch that will mount to the headlight to go from high to low beam.

The headlight will turn on how I have it wired but the second I flip the toggle it will pop the fuse. I was looking at the switch and now wonder if it can handle the power load. See picture. It says 6A and 3A Has anyone and this issue?


It's the last thing I need to get working to get the safety inspection so I can actually ride the bike.

 

Based on the watt rating, looks like high beam should draw 2..5A at a nominal 12 volts. I'm wondering if you have something mis-wired to short?

Do you have a multimeter you can hook in series with the switch to see its amp draw when you turn it on?

What size fuse are you using? Is there anything else on the circuit?

Also, headlights usually use a relay after a switch, because of their high current draw. LED headlights draw less current, so someone else will have to comment if a switch without a relay will work in this situation. That switch is rated for AC current at higher voltage. I believe DC current ratings for switches are usually much lower. However, if the DC current rating of switch is too low (which it might be), I wouldn't think it would cause the fuse to pop immediately, but rather the switch would get hot, melt or arc, and then maybe pop the fuse.

 

Something is wired wrong it it pops fuses that fast.
The center of your switch should be from a 12v switched source. One outer terminal to the low beam and the other outer terminal to the high beam. The bulb will have a ground wire.

 

Ok.. let me get this correct. the 3 wires out the the headlight. 2 will go to the switch and 1 will be grounded(not going to switch.) The middle terminal on the switch is the "Hot/power" wire?

 

it may be your switch. you need a switch that makes contact then brakes contact and makes contact when flipped. you are lighting both high and low at same time

just like the yamaha switch does ever notice the light goes out when you switch from low to high?

 

yes that is correct

 

Thanks.. I think I have my wiring incorrect. I'll correct and then report with results.

 

Correct, providing you don't have the handlebar switches anymore. I do believe you removed them.

 

This worked perfectly. thanks for all the help

 

what did you find wrong?

 

My wiring was incorrect, very incorrect. haha