Headlights & fuses

[Polker]

I went to put a new switch in the other day and I started popping fuses when i flip it on. It pops 5 then 7 then 6. The lights stay on but nothing else that is associated with those fuses do. Since it is on a previous owner installed switch, is there a common way that people run a headlight switch?

[namba209]

First off, the original headlight wiring was NOT fused. So if you're blowing fuses, I would suggest you have direct short in your fuse panel. Best bet is to drop the power panel and check out the wires inside to find the short.

[trlmr]

I am a little confused, GT's don't have a headlight switch inside the cabin. The only switch is for the parking lamps. The switch that turns on the headlights is a microswitch in the headlight mechanism. Did you mean you replaced the relay or the microswitch? Maybe I'm missing something here.

[grslightng02]

Sounds like someone manually wired a toggle switch into your running lights. When you turn the toggle switch on to turn the headlights on, you may be pulling too much electricity through those circuits and burning out the fuse.

My guess is that the original wiring to the headlights went bad, and someone rewired it into the running lights instead of replacing all the original headlight wiring.

[Polker]

It is on a toggle switch, and it is probably pulling too hard to pop the fuses. What is the best way to wire it to not pop the fuses? Direct to the post and an in-line fuse?

[markandson]

You have to use a relay in the circuit to handle the amperage required by the headlights and then use the toggle switch to energize the relay.

[namba209]

Good plan, Jeff, but I would suggest a minimum rating of the relay to at least 40 amp rating, just for added insurance that it will last awhile. Or use two relays, one for each beam on both lights and have the hi-lo beam relay operate the relay. There's been a thread or two on doing that.