Hello all. I have a 2002 AC 300 4x4. For some time my headlight fuse has been blowing - no particular time (turning, stopping, etc), just randomly. There's no movement I can pinpoint that causes it to blow. Put a new one in and it may last 30 minutes or a week. I pulled the front rack and plastic and checked the wiring underneath up to the main harness with the lights on and wiggled/moved all of the wires. Checked each socket for shorts. Checked resistance across each bulb - they were all the same: .6 ohms. All this fuse covers is the headlights and taillight. Voltage across the fuse holder is 11.67VDC (engine off). Voltage at battery is 11.62VDC (engine off). Kinda weird. The circuit pulls voltage from the battery but is also tied to the regulator rectifier, which leads me to my next thing. I pulled the rectifier off and tested it according to the specs in the AC Service Manual. My readings were WAY off from the specs except between the R and B/W wires. First is my rect/reg really bad? Can this be causing the headlight fuse to blow intermittently? Everything else on the ATV is fine and everything else works, no other issues whatsoever. Attached is an image of the AC specs versus mine. Thank you very much in advance for any help anyone can offer!!!
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