2002 Headlight Fuse Blows

I bought a 2002 Vfr over the winter. It had 8500 km on it. I've put about 2500 km on it since. I seems to be in great, near new condition. Problem is that after about an hour and a half of riding it burns the 10 amp fuse for the headlights, instruments, and I believe the taillight is included. A 10 amp fuse doesn't seem sufficient for the 2 low beams which should draw about 9 amps alone at 12 volts, nevermind when the high beams are used. The fusebox indicates a 10 amp fuse should be used. The shop manual I've got shows 20 amps for the headlights, but the fuse is not in the same position/place in the box. There is a discrepancy. does anybody have any info or experience with this problem?

The serial # of the bike does not match any of the recalls by Honda for electrical issues as far as I can see

 

I had the exact same issue and it turned out that the front brake light switch was shorting out when I pulled the front brake lever. Double check the wires on the front brake assembly or as a test, replace the fuse and disconnect the wires from the switch and take it for a ride, but make sure when your slowing or stopping to use the rear pedal so your brake light will activate. To be honest you don't even have to ride, after I replaced the fuse on mine, as I was grabbing the front brake to put the bike in gear, the fuse blew. That's how I discovered the issue.

 

your headlight power is going through a relay. that 10 amp fuse is on the control side of relay. check switchs for shorts to ground and/or a pinched wire in the harness

 

Yes the power does go through relays (one low beam and one high beam). According to the wiring diagram the fuse is on the power side of the relays, not the control side. The wiring diagram also shows a 20 amp fuse for the headlamps so there's a discrepancy between the markings on the fuse box and the wiring diagram. Strange !

It makes some sense that the fuse would be on the power side of the relays since they are likely to draw near 20 amps. The control side will only draw about ~1 amp maximum unless shorted, and even then a 10 amp fuse probably is not going to protect the tiny gauge control wire.

 

hmmm my diagram shows it very different then that

 

Here are two diagrams that will help, note fuse 'F' is a 20 amp for headlights, fuse 'B' is 10 amp for turn signals;

 

Yup, that's the diagram I have, 20 amps in the power load circuit. Any idea why the fusebox on the bike contradicts the diagram ? Guess I should ask Honda !!!

Thanks.