Headlight fuse

Discussion in '5th Generation 1998-2001' started by hawkx2, Sep 5, 2015.

  1. hawkx2

    hawkx2 New Member

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    Went out for a ride today and a little ways in the headlight went out. Got back home, checked fuse. It was blown, okay easy fix. Changed the fuse and as soon as I turned the key the fuse blew again...WTF!!!!
    Has anyone else had this issue? Nothing has been changed on the electrical and all other components work. Don't even know where to start searching for the cause of this. HELP!!!!
     
  2. Knight

    Knight New Member

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    There is probably little chance that this is your issue but is the brake light switch touching the bar?

    I adjusted the brake lever all the way forward. In a design of colossal ignorance, it is the brake light switch (on my 1999 at least) that ends up stopping the rotation of the brake controls. The switch shorted against the bar and blew the fuse. I replaced the fuse without thinking about the cause because I had made no "maintenance" changes. Soon the battery was dead from the short. The brake light switch is on the same circuit as the headlight. Either this is a defect or the wiring exiting the switch cracked from age and exposed the wiring. (I have not inspected the switch yet.) To stop the problem I rotated the brake controls until there was separation between the switch and the bar. The dealer says there is no recall on this switch.

    I wonder if the starter switch can short, aka, the cause was pushing the starter? That is one of the things to inspect.

    If no, the next thing to do is identify every thing on that fuse circuit from the bike wiring diagram. Inspect all of the wiring for a tear or a bare spot shorting against the frame. I am not a guru but I am thinking disconnect the battery, then check the resistance using an ohmmeter between each switch's input and output. When you find the one with no resistance that is the short.

    Keep in mind if the fuse is in, the battery may be currently shorted and draining. Check your battery voltage now. If much below 12.80 charge it. A low battery can harm the charging system. These are reasons not to replace the fuse yet and not to ride the bike until you identify the problem.
     
  3. hawkx2

    hawkx2 New Member

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    The brake light switch was the first thing I checked and it is not the cause. I'm slowly working my way through the wiring harness to hopefully find the culprit. So far no luck in finding the issue. There has to be a bare wire somewhere causing the short. Everything else works. When I put in a new fuse and turn the key it immediately blows the fuse for the headlight. Hopefully I can get it figured out before the weekend.
     
  4. Knight

    Knight New Member

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  5. hawkx2

    hawkx2 New Member

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    The only changes since I've owned it were to suspension. Previous owner had a lowering kit installed. New shock installed, linkage and side stand replaced. That was several months ago. No issues until this past Saturday morning. I've been doing a lot of searching for similar issues, but haven't come across the exact same as mine. Some searches I have found will blow fuses intermittent and/or have other issues as well. My headlight fuse blows immediately when I turn the key and the headlight is all that does not work. I'm guessing exposed wire causing the short...if/when I can find it.
    Still up for and appreciate all suggestions. Thanks
     
  6. rjgti

    rjgti New Member

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    unplug your headlight relays, that way you cut the wiring harness in half. if fuse doesn't blow y
    then you know it is relay or wiring from relay to head light
     
  7. rjgti

    rjgti New Member

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    just saying, will save you time
     
  8. Knight

    Knight New Member

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    Maybe I am misinterpreting something. You said that it is only the headlight that fails. However there are more items on that same fuse.

    With suspension changes I wonder if the rear light wiring is the culprit. Maybe it was pinched during the work or put back in a place where it rubbed against a moving part? I am not sure if the rear lights are on that circuit I am guessing.
     
  9. hawkx2

    hawkx2 New Member

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    Thanks for that tip.

    I would think only the headlight runs off that fuse since the headlight is the only thing that does not work. My initial check of wiring around the shock mount did not turn up anything that could be the issue, but will be double checking after I try the suggestion above from rjgti.
     
  10. rjgti

    rjgti New Member

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    tail light is a dif fuse, don't chase ghosts
     
  11. rjgti

    rjgti New Member

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    headlight is fuse f(20a) taillight is fuse c(10a). do not chase a ghost issue
     
  12. rjgti

    rjgti New Member

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    lower power side of relay(headlights) is controlled by the start button switch which is fused by g(10a)....just saying
     
  13. rjgti

    rjgti New Member

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    hence start button shuts off both high and low beam during crank time but on low current side
     
  14. rjgti

    rjgti New Member

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    fuse f is totally separate
     
  15. rjgti

    rjgti New Member

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    let us know which fuse is blowing, a through g. that will clarify for me as I am trying to hard to appear smart again as I have been told by a kind fellow member
     
  16. hawkx2

    hawkx2 New Member

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    The fuse that is blowing is the 20a fuse for the headlight.
     
  17. rjgti

    rjgti New Member

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    then, if my fellow members concur....pull the relays
     
  18. Knight

    Knight New Member

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    All, I apologize profusely for this. I'll go sit in the shed now.
     
  19. rjgti

    rjgti New Member

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    my sarcasm was not intended for you knight, sorry dude
     
  20. Knight

    Knight New Member

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    Irrespective of what you were actually saying, it would have been correct to point out my error, with no harm done. :)
     
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