I have a 2001 cbr 929. My headlight fuse blew out so i put a new one in. Headlight worked for about a week then blew out again.. It gets to where the fuse blows quicker and quicker. Now the headlight will work fine (brights and dim) while the bike is in neutral. As soon as i put my bike in gear and let off the clutch to start riding the fuse blows and my headlight goes out. I have looked and cannot find any burnt or shorted out wires. The brightlight relay seems to be working fine. I unpluged it thinking it was the problem but the fuse still blew. Every now and then the fuse seems to want to work fine and as soon as i get away from the house the fuse blows and leaves me stranded at night... if anyone has had this problem or has any input please tell me. I got to get this fixed asap! thanks

 

If you have a fuse that's blowing, then you definitely have a short. How are your skills with a VOM (volt/ohm meter) ?

 

dont have one.. do you know how much current the positive should be pulling? and if the bulb is a hid bulb that is tied into the factory harness could that randomly cause the fuse to blow? like maybe when the bulb gets hot? i rode my bike today and it never blew out the fuse.. yesterday i drove it around the same distance and it blew it. after it blew the fuse it just kept blowing it but would only blow when i shifted out of neutral into first and let off the clutch.. but while in neutral it was fine...

 

i had the same problem a while back but the fuse for my gauges you blow, One of my taillight blinkers had chafed and was shorting on the subframe. I missed it every time I looked for it.

 

If your running a true hid, with a ballast, then yes, thats probably your issue. Most hid ballast upon startup will draw up to 20 amps until the bulb is up to full brightness, then it drops down to 3.5 or so.

I would strongly suggest using a relay, with a positive directly from the battery, and use the existing headlight plug as the sensing wire which will turn the relay on. You can buy a universal relay for about 5 bucks at just about any autoparts store.

It may be blowing at random times as each start up of the hid weakens the fuse, then it will just fail randomly.