I noticed that intermittently my head light was switching off and on again. It didn’t seem to be related to anything in particular, like turning the bars or hitting a bump and it was so occasional that I pretty much forgot about it between occurrences.
Fortunately when it got really bad it was daytime, so I got the bike home and pulled the switch block out.
On inspection of the wiring diagram it appeared that the green wire serves 4 earths, so I withdrew the pin from the connector block and the green wire pretty much fell out of the sleeve.
The pics show that the 4 earths from the switch gear are crimped and heat shrunk to the single earth wire from the connector block. This crimped connection seemed to be exactly where my wires were bending round the fork and this repeated movement had broken the wire.
The pic on the right is as it came off the bike.
I took all the pins out of the block and removed the sleeve, re-made the connection with solder and heatshrink, which made it too fat to fit into the old sleeve with the other wires so I took it out through a hole in the sleeve and ran it separately in some old sleeve I had laying around and it's all working nicely again.
