I've had this same thing happen a couple times on long trips, always when I
was running the brights. I believe there are two things involved: 1/ the
heat experienced by the dash-light switch (it is cheap/poorly engineered)
makes it overload, oxidize, carbon-up, and not work; 2/ the ignition switch
wears out and affects the headlights ability to function. I have replaced
the dash light switch and experienced the same thing again (light failure)
and have all the "stuff" to install a couple relays in that system, which
results in lower voltage crossing the switch (it becomes an on/off only
device) and boosting current to the headlights, making them brighter. I have
actually jiggled the ignition switch and had the lights come on when they
would not otherwise. Thanks to Frank Condelli, there is a nicely laid out
procedure description at: http://members.aol.com/Fkc43/mechanic.htm

Good luck, Bob Stevens
'91 Westy

Happy is he who bears a god within.
-- Louis Pasteur
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