Help - Headlight fuse keeps blowing

[akey]

Does anyone know of any common problems with the headlight wireing as my 02 Girly keep blowing fuses.  They dont blow instantly but after a bit of time (say 5 min of riding or so).  I have had the front cowl off and looked at the wireing up to the bulbs and cant see any worn through (my first guess).

Im gonna replace the fuse (again) and ride home with the lights off tonight to see if its before or after the relay and switch.

Any other thoughts.

[akey]

Tried it tonight and its blowing fuses as soon as the ingnition is on.

Striped the front end, put some protection where the wires cross metal, but cant see any damage so far.............. now its not doing it anymore fingers crossed.

Will see next time I'm out I guess.

[Putts255]

Definitely got a wire that is loose and grounding out somehow.  I would get a hold of the wiring schematics and locate the wires for the headlights and trouble shoot these wires at any junction or possible abrasion point.  May even be at the headlight connector.  

It will be a painful and tedious process but you should be able to find it.  It could be that one of the wires was stretched too far and you may not even see it.  Check where the harness may have been stretched.  

Good luck!

[D-Fuzz]

A similar thing happened to a buddy of mine, turned out to be the bulb itself was causing the short.  There was some corrosion on the contacts that was creating enough resistance to pop the fuse.  He put in a new bulb and it hasn't happened since.  It might be worth a try, bulbs are pretty cheap.

[akey]

Thanks for the replies guys.

Its not the bulb as it blows the fuse with the lights switched off (or it did).

I traced the wires up to the relay and removed any tight wires, looking for any wear, but couldnt find any worn through insulation.  I wrapped up any area that were close to metal work and ensured that there were no tight runs and it seems to have sloved it, although I havent taken the bike for a decent length ride yet.

[D-Fuzz]

Is there something on UK bikes that allows you to ride without the lights on, or is it a switch you installed yourself?  Over here, the lights come on with the ignition.

[Totos Tiger]

Pull the relay out.  That will tell you if the short is before or after the relay.

Use an ohm meter or test light to see if the wire going to the headlight is grounded with the relay out and the ignition off.

That should narrow it down a little.

[John Stenhouse]

Is there something on UK bikes that allows you to ride without the lights on, or is it a switch you installed yourself?  Over here, the lights come on with the ignition.

Yeah, merry old England believes in choice, there is a switch on the bars for headlights, sidelights or nothing at all. Doesn't matter where you put it tho', all cage drivers are blind.

[Timbox2]

Is there something on UK bikes that allows you to ride without the lights on, or is it a switch you installed yourself?  Over here, the lights come on with the ignition.

It depends on the year of the bike, my 2005 UK bike has lights on all the time too.

[akey]

Sorry yes the 02 tiger has a light switch on the RH handlebar.

[metalguru]

For those who would like the option of switched lamps, the early switch can be fitted to the later non-switched and can be bought quite cheaply on flebay. (855 & 955 efi)