yes my spare harness is brital as and the insulation falls of if you bend the wire too much ,and it has green rot at all the crimps and joins !

You might be suprised how far your wiring has corroded on the actual wires, it is getting old.

yeah i have to find where the earth is for the lights. im thinking that is the problem.

Best bet is to open the wiring loom seperate the wires so you can see what is what and replace the wires and connectors to the lights, extra earth will help if in doubt. The issue seems to be resistance and this creates heat so bad earth, corrosion or bad connections should be rectified, maybe add a relay aswell but only after checking the above.

yep checked it no corosion there and it is blowing 15A fuse. as soon s the lights go on i gets hot as! not to mention the high beams you cant touch it... then pop fuse gone.

Nah, the stock wire is no problem.

If the fuse gets hot, it is probably a little corrosion at the fuse box. Clean it carefully where the fuse fits in, and check the wire connections at the fuse box.

Or it could be the lights are drawing too much current. It should be a 15A fuse.

i noticed that the earth lead from the battery goes to the engine but there is only a thin wire that then goes from the engine to the body???? im thinking this should be bigger then this?

Ure best bet is to earth the headlights straight to your battery, will always have a good earth that way ;) or get a multimeter and measure the resistance of the circuit and use ohms law to see if the current draw will be more than the fuse rating, I can assure u it will just be a Shiat earth

ok thanks DJF280 will give that a try tomorrow , will let ya know how i go cheers for the other replies!

Hi i dont know if im much help but it sounds like you have a short circuit. Check your earths im sure the head light earth point is at the guard indicators. May be disconnect left side light and see what happens and then vise versa that way you might be able to eliminate one side and get closer to the fault.