15A Headlight Fuse Keeps Blowing on 1100EVO

[gjsnyc]

I've had my 2012 M1100EVO for 2K miles.  While on my trip down to the dragon, my CEL came on.  After returning i took it for warranty work and was informed that there was a bad a relay that it was replaced, under warranty.  When i went to pick it up, the CEL went back on and the headlights cut-out.  They replaced the 15A fuse with a 20A, the rationale being that my PIAA hi/low beam aftermarket bulbs (purchased from monsterparts) were drawing extra current.  The bike ran fine until i started it back up.  The fuse blew again, the headlights cut out, and my CEL flipped back on.  This time, i replaced it with a 15A and rode it around.  Next time i started it back up, same thing occurred once again.  Fuse blew out and headlights were non-functional...CEL on.  Tomorrow i'm going to be replacing the aftermarket bulbs with originals to see if the fuse continues to blow.  If it does, they have clearly created a short somewhere along the line upon replacement of the defective relay.  In the meanwhile, does anyone have any common experience or has heard of something like this happening to their bike or others?  The bike absolutely worked perfectly fine for my first 1900 miles with the bulbs installed on inception.  Thank you

[Howie]

What is the wattage on your PIAs?  If they are the same wattage as OEM they draw the same current.  Never replace a fuse with one of higher amperage, for sure if the wiring is not the proper gauge for the higher rating, and it rarely is on a motorcycle.   If you have a short and it was not caused by you it is a warranty item.

[ungeheuer]

They replaced the 15A fuse with a 20A, the rationale being that my PIAA hi/low beam aftermarket bulbs (purchased from monsterparts) were drawing extra current. 

Why not just use a piece of #8 fence wire?      Find another dealer.

I'm betting your issue goes away when you reinstall the stock headlight bulbs.

[suzyj]

The reason the fuse is there is to protect the wiring from overheating if there's a problem. It appears there was a problem, and rather than fix it, they've just put a bigger fuse in. So then the wiring gets hot, the insulation melts, and you get lots of shorts, causing more blown fuses and more damage.

For reference, a stock 55W globe draws a little under 5A.  A 15A fuse is three times the nominal current.

The rule of thumb with fuses is that if one blows, replace it. If the replacement blows, find the fault.

[gjsnyc]

Just pulled the headlamp, both the H1/H7 PIAAs are 12V55W rated... same as OEM.  This can't be the problem.  All the sockets look pristine and do not show evidence of overheating/melting.  Looks like i'll be taking it for more warranty work at a different dealer.

[Autostrada Pilot]

The reason the fuse is there is to protect the wiring from overheating if there's a problem. It appears there was a problem, and rather than fix it, they've just put a bigger fuse in. So then the wiring gets hot, the insulation melts, and you get lots of shorts, causing more blown fuses and more damage.

For reference, a stock 55W globe draws a little under 5A.  A 15A fuse is three times the nominal current.

The rule of thumb with fuses is that if one blows, replace it. If the replacement blows, find the fault.

Great info, SuzyJ (btw, you seem to be an absolute fountain of knowledge).  I've always wondered what a stock bulb pulls.  I will now be replacing my stock bulb with the PIAA since it won't draw hardly anymore juice.

[manwithgun]

For reference, a stock 55W globe draws a little under 5A.  A 15A fuse is three times the nominal current.

In case anybody was wondering,  Amps X Volts = Watts;  or rather 55watts divided by 12volts = 4.58amps....

[gjsnyc]

Disconnected the entire headlamp and turn signals completely (this rules out the PIAAs and LED parking lamp).  Still blows the fuse upon twisting the key for ignition.  Spoke to the dealer who said they pulled the relay under the tank as it was corroded and cleaned it.  Inspected it myself as well and the relay looks okay (but found my fuel tank only attached by one nut and several loose bolts....fail).  Interesting that the socket these two relays plug into says 'BMW'.  I'm thinking there is a short or something being sent from the ignition itself.  This will be going back to warranty work at Ducati NYC (although they are backlogged for the next 2 weeks).

[Howie]

Try Rockwells or Gold Coast. 

[DucNaked]

The one bolt holding the gas tank is normal. Ducati only installs one side.

Check the main harness coming up behind the headlight. This harness has been known to chafe and cause problems.

[dwl19]

i have an 1100evo and having issues with my headlight cutting out too.  it just starting happening (i've had the bike for 9 months and <3000 miles).  the fuse is not blowing, but the light cuts in and out *sometimes*.  i noticed i can make the lights flicker if i jiggle the connector right behind the light, but not all the time.  ugh!

[Raux]

(but found my fuel tank only attached by one nut and several loose bolts....fail). 

the small bolt on the right side insert and the bolt under the seat are the only two that are used. the left side is loose (likely for expansion)
also it helps to grease up the parts inserted into the rubber... pain to pull the tank if they are dry.

[ungeheuer]

Disconnected the entire headlamp and turn signals completely (this rules out the PIAAs and LED parking lamp).  Still blows the fuse upon twisting the key for ignition.  Spoke to the dealer who said they pulled the relay under the tank as it was corroded and cleaned it.  Inspected it myself as well and the relay looks okay (but found my fuel tank only attached by one nut and several loose bolts....fail).  Interesting that the socket these two relays plug into says 'BMW'.  I'm thinking there is a short or something being sent from the ignition itself.  This will be going back to warranty work at Ducati NYC (although they are backlogged for the next 2 weeks).

Any update?