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Blowing a fuse everytime I turn my headlights on

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7.8K views 7 replies 4 participants last post by  SeaDogBRR  
#1 · (Edited)
Why am I blowing my 20 amp light fuse everytime I turn my headlights on? The machine is 100% stock no light bars or winch drawing power. Checked the ground and it’s good traced the wires and they look good same with the relay. I put a 30 amp fuse instead of the 20 amp fuse and it worked fine but wonder why out of no where it blew the 20 amp. Thanks in advance
 
#3 ·
A fuse blows for only two reason
#1 short circuit which causes a higher current draw than the fuse is capable of handling,
Look for chaffed or broken wires rubbing on metal parts, (ground)

#2 overload of the circuit, if current exceeds the amp rating of the fuse it will blow, was any accessories added to this circuit? Sometimes a defective bulb can cause this, in the case of electric motors tight bearings can cause higher current draws.

Somtimes looking at a fuse closeup will give you a indication of either 1 or 2 above.
In the case of a short circuit the fuse will blow instantly somtimes leaving black residue on the part of the fuse where you can see the element. In the case of #2 the element of the fuse would have just opened.
 
#4 · (Edited)
A fuse blows for only two reason
#1 short circuit which causes a higher current draw than the fuse is capable of handling,
Look for chaffed or broken wires rubbing on metal parts, (ground)

#2 overload of the circuit, if current exceeds the amp rating of the fuse it will blow, was any accessories added to this circuit? Sometimes a defective bulb can cause this, in the case of electric motors tight bearings can cause higher current draws.

Somtimes looking at a fuse closeup will give you a indication of either 1 or 2 above.
In the case of a short circuit the fuse will blow instantly somtimes leaving black residue on the part of the fuse where you can see the element. In the case of #2 the element of the fuse would have just opened.
After further review it appears to have black residue on the blown fuse which points to you’re first reason. I let the machine sit over night last night and this morning I put a fresh 20 amp fuse in and it didn’t blow but I also see that both headlights work on low beam but only the one works on high beam. The one appears to have a broken element inside. I swapped bulbs into the opposite headlight to confirm it was the bulb and not the harness and got the same result. So the black residue points to you’re first reason but the broken bulb points to you’re second. Also I have no extra accessories it’s 100% stock. I’ve also double check the lines and can’t find anything chaffing. I’ve also ordered some LEDs since it was already on my list
 
#5 ·
After further review it appears to have black residue on the blown fuse which points to you’re first reason. I let the machine sit over night last night and this morning I put a fresh 20 amp fuse in and it didn’t blow but I also see that both headlights work on low beam but only the one works on high beam. The one appears to have a broken element inside. I swapped bulbs into the opposite headlight to confirm it was the bulb and not the harness and got the same result. So the black residue points to you’re first reason but the broken bulb points to you’re second. Also I have no extra accessories it’s 100% stock. I’ve also double check the lines and can’t find anything chaffing. I’ve also ordered some LEDs since it was already on my list