Reply to "Headlight switch blues 😬"

Is there a relay on the light switch circuit? The relay does reduce the load on the headlight switch, which in turn prevents damage to the plastic tab inside of the switch. What you are describing sounds like a damaged internal plastic tab due to heat. If you have headlights that are a higher output than the factory lights, then there is an increased load on that circuit, which puts more load on the light switch. I installed a relay on my headlight switch years ago, but still had a switch failure. Perhaps I didn't wire the relay correctly. The failure occurred on a narrow winding road at night, which does get your attention when the headlights go out and the headlight doors begin to close. I later installed an old fashion metal generic push pull light switch and never had another problem. I am sure that someone here has a better idea than I do.