Hey guys I don't remember there being a relay inside the headlight switch. Perhaps I needed to look a bit harder...anyway wiring up a new relay didn't hurt as it provided new copper and a direct path from the battery. I guess a good check of your earthing situation is a great idea as well. It always seems to be the earth cct that gets neglected. Why can't it be something trickier?

Andy.

Merry KWANZA!