What fuse for the EB H4 headlight relay kit? - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 9 Old 08-14-2013, 05:07 AM Thread Starter
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What fuse for the EB H4 headlight relay kit?

I tried searching and found no amp rating reference even on EB's site. When I was installing my PC-8 fuse block and the H4 dual headlight relay kit with the headlight cut out from Eastern Beaver, I lost track of what fuse came with the relay kit. I was pretty sure it was a 15A so I went with that. 500 miles later, and on our 1200 mile trip to Napa Valley, I go to start the bike and I have no headlights. I didn't know what happened and it was dark so I unplugged the kit and plugged my stock sockets back in to have lights. When I finally get daylight and time to look I see nothing wrong other than the blown 15A fuse. I want to make sure that I shouldn't have had the 20A in there first before messing any more with it. I know the relays are rated to 20A but if the kit was meant to run 15 and I'm going to be blowing fuses then I need to dig further...when I get home. If I should have had 20A in then I can do that and save some wattage, with the cut out, for my heated gear, GPS, etc.

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post #2 of 9 Old 08-14-2013, 07:30 AM
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20 amp fuse.

-Tom (DL650AL2) (KA1TOX) (E-I-E-I-O)

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post #3 of 9 Old 08-14-2013, 11:00 AM
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Two 55 watt low beams = 110 watts
110 watts 12 volts = 9.2 amps
Two 60 watt high beams = 120 watts
120 watts 12 volts = 10 amps
Flash-to-pass = 9.2 amps + 10 amps = 19.2 amps (good thing it's momentary)

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post #4 of 9 Old 09-25-2013, 07:54 PM
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Once again, a wealth of knowledge on this site. I just got done reading my EB instruction sheets for the 4th time thinking that somehow I missed the 20a fuse thing.........

thanks again, strommers!

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post #5 of 9 Old 09-25-2013, 10:02 PM
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I just received today my EB H4 kit with dual relays and battery connection. Jim included 2 20A fuses for the inline fuse holder. One to use and one spare!
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post #6 of 9 Old 09-26-2013, 12:05 AM
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I installed my EB H4 kit tonight. Very easy, since I got the PC-8 version of the kit. The hardest thing was figuring out a good way to stash the 'junk' in the fairing without any of the control cables jostling the EB wiring. After a few false starts, I figured out a layout that keeps the EB wires tucked up and out of harms way from the control cables that move when the handlebar moves.

And yes, it's nice that EB includes spares with their kits - that's quality.

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post #7 of 9 Old 09-26-2013, 09:16 AM Thread Starter
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I found my problem but forgot to update here. My HL relay ground to the PC panel was loose. Don't know if I just didn't tighten it on installation or it loosened on the trip. But I'm figuring that plus the 15a fuse I used was what popped it. No issues since with the 20a.

FWIW I used a length of trailer light wiring, 4 stranded wires in it's own sheath, to run my circuits along the frame under the tank on the left. I had it on hand at the time, it was easy enough to run without any tricky fishing.
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post #8 of 9 Old 09-26-2013, 09:38 AM
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Is the trailer wiring heavy enough to handle 20 amps? I would want to check. I think I used #12 wire for my headlight relays. After all, part of the reason for the headlight relay setup is to get maximum voltage to the headlight.
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post #9 of 9 Old 09-26-2013, 01:17 PM
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Ampacity (how much amperage a wire can carry) is all about heat. The usual household wire ratings are for wire wrapped in a 6" fiberglass overcoat. An example--the overhead wires carrying 200 amps from the power pole to the mast on my house are much skinnier than the wires that connect to them and carry that electricity through my walls to the house power panel, maybe 3/0 in the walls and #1 overhead through the air.

Here's an ampacity chart that shows #12 copper wire good for 41 amps in free air and 23 amps when enclosed, for example. Wire-Gauge Ampacity - Transwiki

On bikes with the wire fairly well open to air, it can be considered safe to go at least one wire size smaller than usual household wiring--#14 wire with a 20 amp fuse.

"Older people who are reasonable, good-tempered, and gracious will bear aging well. Those who are mean-spirited and irritable will be unhappy at every period of their lives.

"Let each of use properly whatever strengths he has and strive to use them well. If he does this, he will never find himself lacking."

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