If your poping a fuse instantly, More than likely depending on what wire touched grounded and when a fuse pops that quickly it's grounded out.So somewhere a wire is touching metal OR another wire. Unless it is not wired correctly. You will need to remove the headlight and check for a possible melted wire to a another. Also might want to get another relay to replace 8 bucks or so at the Dealer or American Sportbike .com/ That said you need to (Mark) the old relay and with a test light check the wires feeding it.Now you have a grounded wire and it is a power wire at that,OR the relay is bad. It's a small area so it will take a little time to find it. I would if it was here in the shop would start right at the headlight that was modded and work back from there towards the steering.Then to the Relay box [left side]on Stock Bike. There are 4 of them. There are no shortcuts to electrical so make sure the power wire to the headlight going to the keyswitch on isn't melted to the fuse box wire. BTW-check the high beam wiring as well.I realize you just did some mods so take your time and you will find it. Even when all new & rewired it doesn't mean the wires are now ok,or you would not have this problem.This type of electrical problem is more about Visually checking the wiring first then going from there. Remember if your keyswitch is off and you popped a fuse, then power was still (on) some where and that tells me a possible wrong wiring or grounding situation. There should be no power when the key switch is off in this area. If key is [off] and it blows a fuse then you have ign., power wire grounding out to either metal, or another wire. Wiring is a tricky deal and all we can do is give you ways to solve the problem.Not all of them [suggested] will pertain to your problem but these tried practices with some patience you will get you in the right area to the problem.Hope it is an easy fix.~Jimi
