I installed a set of BTS HID replacement headlights about a month ago. I used the supplied plug & play wires to plug into my factory headlight switch and wiring harness. It also replaces the factory 15amp headlight fuse with a 20amp. I opted not to use the optional new wiring harness with relays. All seemed fine with little use. I went on a night ride and when I first turned on my headlights only one came on. I turned them off and back on. Both lit but then blew the headlight 20amp fuse. BTW - I am running factory battery, no other additional lights or stereo except 3 LED tail lights in rear roof wing. I replace the fuse and both lights lit fine and stayed on. After about 30 min of riding my battery light started to flash. When I came to a stop and at idle my headlight fuse blew again. I replaced it and it immediately blew when I hit the switch. I thought that HIDs drew less power? Never the less I thought it was time to upgrade my stock batery with a full size Optima.
After the swap out I hit the switch and blew the healight fuse again! I tested all wiring for shorts and found none.
Here is where i thought I should re wire using the optional relays and new wiring harness included in the HID kit. After that I hit the switch. This time I didnt blow the fuse but no head lights Nothing! Very frustrated after working on it for 4 hours incld the battery swaped so I parked it.

Has anyone had this issue before? Please give me some things to test and look for. This doesnt make sence to me when they were working fine for a while but why did it drain my factory battery? HID's are supposed to be less power after ignition of light? Never had a problem with my factory headlights killing my battery. Did I get a bad kit? Bad ballests? I know I need to test to see if I have power to the plug that goes to the ballest. But what after that? Any help would be appreciated.

could be alot of things .... a bad connection drawing more amps...bad ballist .... but when starting hid's for a few sec draw more than the stock lights but after warming up for a min or more draw less ... so 1. you may have to many things drawing power on that circuit ...you said you have otheir lights for the rear are they on also? never leave the headlight switch turned on if you turn the key on and try to start it their is way to much draw and will pop the fuse hook one of the lights and ballist straight to a battery and see if it works .... unplug both ballist they are positive and negitive but most are not marked some people have hooked them up wrong a few have marinkgs on them after disconecting try plugging in 1 and try then try the otheir if it blows a fuse you might have a bad ballist this is a place to start

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2006 silverado 2500 hd
2006 additude toy hauler
2008 polaris rzr
2006 suzuki ltr450
2005 kawisaki kfx700
2003 suzuki z400
2003 honda ex250

triple check your connections and your harness, make sure nothing is shorted or kinked. same thing happen to me, hids blew my fuse 3 times. turned out the tail light harness was kinked between the bed supports and frame

Are the wing light(s) wired to the front HIDs? I think that is your problem at this point. Add a switch and turn the lights on independently waiting a few mins to start the wings.

I’ve had same issues with my stock HID replacements (Only one turning on and blowing fuses) but they seem to do fine if I just start the engine first and go to 3K rpm when I fire up the lights. I don’t have any other accessories on my RZR and I’m using the stock battery at this point. I bumped the light fuse up to 20 amp and my chassy/main(whatever was 20 or 25) that also seems to blow to 25 or 30 amps.

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2006 Silverado 2500HD Custom Truck
2007 Weekend Warrior FSW3200
2008 Ranger RZR 800 EFI (w/kids rear bench seat!)
2006 Honda CRF 450X (Set up for a BigPig.)
2007 Apex MRX100 (Taylor's New Ride!)
2001 ETON 50 ATV (Taylor's Old Ride!)
Coming Soon (Something for KatieBugs!)

My rear led lights are not hooked up to the headlight switch. They are wired up with the factory tail/brake light harness through a relay. So they come on when the ignition is turned on. HID's on same circut as factory front headlights.

Will,

This is Josh. Let me know what happens. Never heard back from ya. Give me a call so we can get this figured out.

Josh,
Its been 113 deg here in the afternoons so I havent been to excited to work on it when I get off work. I am going to dive into it Sat AM. I have a few things to test out with a new meter I picked up. I will let you know. Thanks!

Dang... 113. Its like 90 here today and I am dying. Definately let me know the outcome. We will do what it takes to make it right.

PS... On a side note... I hate you becuase you have a sick azz RZR. It looks really good.

The fact that the light kit came with a 20 amp fuse to replace the 15 amp fuse says that the lights take more current to operate. the factory wires may be to small for the current draw, they get hot and the fuse will go away.
if your light kit came with new wires use them, take a little time take it all apart, clean while you are in there, buy some wire loom make it look like some who knew what they were doing did the job.
HAP

OK folks... found 2 problems.
1) Wiring instructions for the relays were wrong. Everything was right except the last step. The 2 white wires (instructions said blue, no blue wire) coming off #86 & #85 posts on relay. #86 goes to 12v wire from head light switch (green polaris wire) & the other white wire (off #85 post on relay) is not needed. Wrong... it needs to go to GROUND.
2) One of the ballasts were bad. Even after wired correctly as soon as light switch was turned on I would blow the in line fuse to battery going to that ballast. Even swiched bulbs and relays still same result.
Contacted Josh at BTS. Josh is sending me a new ballast 2 day air. He couldnt believe no one else has contacted him about the instructions being wrong. He was very cool and willing to help. That leads me to believe no one is using the relay method of wiring for the HIDs. Or they just couldnt figure it out like me with out help. Now knowing what I know about HID's and how they work I would definatly recommend every one who has the factory HID headlight kit needs to wire using relays. If you dont have a problem now, you will. Especially with the lack of good charging system on the Razr. Even though they take less to run, the initial start up takes alot more power. People are saying that they have to rev up thier motors or start driving before they hit the switch. By using the relays coming striaght off the batteries you dont have to do that. Hit the switch and even when the razr isnt running BAM I got light!

Will,

Went out today via FedEx. Sent the tracking info to your personal email address. Has a delivery date of Wednesday. Let me know if you have any questions.

Where did you buy the lights from?

BTS lighting off Ebay. Josh was way good about it. Called me right away and tried to help over the phone. He is sending me a new ballast 2day air with no question. Great customer service. Said it was only his 2nd bad ballast out of 240 kits sold. Not bad.

Very cool....

Keep us posted how you like the setup. I'm in UT and will probably be giving Josh an order not too far down the road.

I just finished my newest install last night and will post pictures a little later tonight to show where and how I did my BTS setup. I made sure I documented everything for Willgrizzle just in case he didn't fix his yet.