[RideADyna]

Just a couple of observations: (1) Dielectric grease is INSULATING not high conductive. If you are using it to improve conductivity, you are defeating your intentions. Use high conductive grease for those jobs. (2) I have had one instance where the plug at the headlight had overheated and gotten loose. Result, intermittent headlight. You might want to check there.

I fully agree. Even though you may have voltage at a connector is the connector loose? Make it tighter by using your pliers and pinching the connector where it slides on. You replaced a lot of wires so that should eliminate a broken wire within the insulation. But, sometimes not all strands are broken and you will get voltage but for a load you won't get what you need. I would also clean all connectors with electrical spray. Also make sure your highbeam switch on the bars is making good contact when you switch from high to low beam.

I've said this before. My son-in-law and I ride identical bikes. But, mine is newer and has a cover for the fuse box. His does not. His fuse holder got corroded and though the main fuse was good it was not making good contact in the holder. The dealer could not figure it out. He comes home all disappointed. In 30 minutes I fixed the problem by spraying the same stuff you clean air conditioning coils into the fuse holder and then rinsed it off. I took each fuse and cleaned them and he has had NO problem since. Take a piece of nylon cloth and cover the holder to keep it cleaner inside.