Quote:
Originally Posted by harleynut
I had a similar problem. Every time I stepped on the brake, I blew the fuse. Turns out my new (junky) brake light switch would short out internally. Put in a new (junky) switch......problem solved.
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A couple guys in our club had the same problem several years ago. The one terminal would short to ground due to missing or poorly placed insulators, or the contact strap hit the side of the case.
The fuse can blow even with the generator supplying the needs because a dead short will overload the system and attempt to draw a heavy current from the battery. Since it happens with the lights off, you can skip the headlamps for now, but do look inside the headlamp switch for stray wires touching the cover. Also check the ammeter for poor insulation inside the case. If you have a repro terminal block, check that the two terminal screw heads aren't touching the firewall.
A poor connection at the fuse can cause excess heat and melt the fuse near the end cap.