It sounds like a "Bi-metallic strip" which work the same as your common automotive circuit breaker. They do get old and intermittent. IIRC, it is part of the headlight switch. Pull in out and have a look. If you have upgraded the headlights, you may be trying to draw more current through the switch than originally designed.
A good option would be to relay your headlights so that the original switch on draws relay current.


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