The culprit was me. I unwittingly reversed the wiring on the headlight. So it all worked while the headlight was hanging out of the shell but when I put the headlight in the shell the fuse shorted out.
Simple, now I am getting my head around the wiring. Brown = ground.
Its been a good tour around the headlight, and beyond. Connections tidied up and now on to oil change grease and tune!!
