My headlight fuse blew. I replaced it and as soon as I went from Hi beam to Lo beam it blew again? Any ideas? I don't know where to start. Thx

 

I'd pull off the front fairing and start looking for broken/cracked wiring. Had a friend with a 2004 that had a very similar problem. It can be a bit daunting though since there are a million wires under there.. but trace back from the headlight and see if anything looks cracked. My friend found several cracked wires with exposed metal but it actually turned out to be a loose wire in a connector that was the ultimate issue.

 

Check your pins and sockets at the headlight first. Some dielectric grease can help here. Be sure they are not burned and they go on relatively tight. If it is only doing it when you flip the switch that would be the next place I would check. Also make sure you have the correct amperage fuse. I see you have truck lights. They should not pull enough current to blow a fuse. Might Google issues or call TL.

 

You have something grounding to that circuit. Make sure you have the correct bulb. If it wasn't blowing before the change then it really shouldn't after.

 

james71.. any work lately to the handlebars or the controls on the bars?

 

ok.

unplug the light.

move the switch from high to low...if the fuse holds, the wiring is ok.

now shake the wiring...if ok, then unlikely that you have a chafed wire.

plug in the light...if it blows then your light is the problem ( if you changed lights as mentioned above, put the stock back in to further test for faults and so you can keep riding while sorting out what to do).

examine the blown fuse.

IF the inside has carbon marks or metal spatter, than you have a short circuit. if the fuse material just seems to have sagged and parted, then the circuit is overloading.
If the fuse is the correct value for the circuit and the load- that indicates a problem in the bulb, esp since the high beam draws more current ( amps) than the low beam.

mike

 

My headlight went bad and blew the fuse. The low-beam filiment broke and was touching the high-beam filiment.

Check the bulb

 

Check the front fender lamp. I had a friend with an early 2000's EGC where the wiring clip inside the fender that holds the wire away from the wheel came off, and the wire chaffed against the tire. Fuses kept blowing until I found that wire for the fender light with the insulation missing.

 

Thanks for all the tips guys. The fuse was blown before I changed the lights out. I got the new lights in and swapped them out before I had a new fuse. Once I put the new fuse in and went from Hi to Lo it popped. I only had the one extra fuse so that was the end of that last night about midnight. I picked up some more fuses today and I'll try the suggestions from this post tonight. I do remember noticing my front fender tip light was out and I whacked it a few times trying to see if it would go on right before this happened. I guess thats where I'll start. I'll update in the morning.

 

Agreed with this method. It could simply be a bad bulb.