Headlight fuse blown & again

[Paul2bikes]

TS ran lovely last time out, done nothing to it since. Went to start it on Friday, all looks normal on dash, usual lights on & needle sweep, fuel pump buzz, pushed starter, zilch, can hear a very faint click. Then realised headlights not on, blown fuse 6, replaced the 20amp fuse, blown again, like a dead short.

Any clues or pointers as to what the problem might be will be gratefully received. Electrickery is the work of the devil himself.

Edit: Bit more probing, switch to main beam & lights on, flick to dip & fuse blows.

[seangee]

Pull the headlight relay and try again. At least that will narrow it down.

[Sidewinder]

Headlights don't come on til engine running on Sport.

You can bring them on by pulling clutch while switch ign on.

What type bulbs do you have, halogen or LED etc?  Pull or disconnect both low beam bulbs and see if bike works ok.  If it does check each bulb with 12v source.

[Paul2bikes]

Ok, thanks fella's. Bit more probing. Bulbs are standard Osram, one eom, the other replaced with identical Osram bulb 2 years ago.

Pulled both dip bulbs & checked on bench battery, one fine, the other went bang & blew apart, fitted new bulb thinking all sorted now. Another new fuse in situ, switched ignition on, blew fuse.
4th fuse fitted, flicked onto main beam ignition on, tried starter, all fine, flicked back to dip while running & ok lights on, engine still running, not blown fuse. Flicked main/dip a few times no problem.

Now then, I wonder, if I try to start on dip as I did last time, but no, all good, worked fine, just tried several times & no problems.

Now worried & confused, I've had a bulb gone before as said above, without any issues, just replaced it, as we would. If it had been ok after fitting the new bulb I wouldn't be worried, but seeing as it blew the fuse again, & now it doesn't, thinking is this one of them that's going to come back at me when I'm a long way from home. Why should it have blown that last fuse with the new bulb fitted & now it all works fine, back to normal. 

Lucky it happened at home, Friday I was all packed up, togged up & off to a rally in the Brecon's when it wouldn't start, I just swapped the luggage onto the 800 & thought I'll sort that when I get home, expecting it to be a loose battery connection, no such luck.

Thanks very much for the help & pointers,  you all know me & electrickery, I'm ok with battery stuff having worked in the industry, beyond that. 

 

[Paul2bikes]

BTW, the lights do come on with the ignition on my '14 TS, they don't come on until engine starts on the gen2 800, so likely the gen 2 TS is same, I don't know.

[Paul2bikes]

You can see in the pic after the glass blew to bits, how the bulb had a dead short, all the circuit had melted leaving the 2 prongs fused together. Hence fuse blew, which also knocked out the starter.

[mustangpilot]

Paul, have you checked if any DTC fault code P1619 or P1620 is stored?
Easy to check by selecting the UP scroll button and SET button together and switch ignition to ON. This will show any stored fault code on the instrument screen.

[Paul2bikes]

Originally Posted by mustangpilot

Paul, have you checked if any DTC fault code P1619 or P1620 is stored?
Easy to check by selecting the UP scroll button and SET button together and switch ignition to ON. This will show any stored fault code on the instrument screen.

Just tried that, screen normal.

[ZuluTiger]

Had a comment but decided it was wrong. Hope you find something!

[Paul2bikes]

Originally Posted by ZuluTiger

Had a comment but decided it was wrong. Hope you find something!

  I'm hoping I don't.