I have a 2005 Sportster 1200 and every time i put the high beam on it blows the fuse. I know the easiest way to fix it is to not put the high beam on, which i have been doing for about a month now but i was wondering if anyone else has had this problem and if anyone has any advise on a better way to fix it than to not use it fix.

Thanks, Matt

 

Only one thing will do that... a direct short to ground.

Check your high beam power wire... I'll guarantee it's shorted somewhere. If you know how to use a multimeter, you can ohm this out and isolate the problem area of wire.

 

I totally agree.

 

Pull the light outta the headlight bucket, and look very carefully for wires that are chafed through the insulation. Dollars to donuts - this is what's causing your problem.

 

Also check inside the switch housing and where the wires come out through the dimpled area on the bar. If the switch housing got rotated, it could be pinching the wire.

 

What they said.

 

Assuming that you're not the original owner, make sure that the stock 60/55 watt bulb wasn't replace with a higher (100) watt bulb and that the bulb socket isn't melted. The higher wattage bulb will literally melt bulb socket.

 

For sure:

 

I also had this happen. It took 2 years but it finally melted just like that pic