Two things come to mind

1 check the connections at the bottom of the ignition switch. Take it off and make sure each terminal is tight and that the gang connector is not melted


If it looks like this you will need to take it apart and trim the melted plastic away and replace the terminal
On my 906 it was so bad I had to replace the switch as well,details on how to do it are in the FAQ I would also suggest you wire the headlights directly to the battery if you have not done so already,it will help prolong the life of this hard to find part

I have found this to often be the root cause of the infamous hiccup while cruising

2 check the secondary ignition and pay attention to the routing looking for gray discoloration anywhere they contact the frame

thanks for the info .i will pull the switch and check it out.i ordered a new left bar control switch that has a headlight off switch. i will do the relay then for now i will just leave it unpluged. i have not done the coil rewire yet but i am going to start
prob,tonight.

they should have zippers not body panel screws lol.

Hey Bob
How did you make out with this ?

got busy at work will not be able to start project till sunday