I’m still stuck on the switch assembly. If you can leave the switch partially on and it works fine for extended period of time without quitting there is something interrupting the connection when fully on. I’m not sure if stock switch assembly works with LED but assuming they will, do you have a second bike you can borrow switch from? Unlike me, most guys on here have several bikes. Probably wouldn’t have to install on handle bar, just wire it in to test. There is also the option to just get a new switch. Stock ran me $45 for aftermarket. Around $120 for OEM if I remember correctly.
I have recently replace both LH and RH switch assemblies, fuse box, and ignition switch cap. Most of them “looked” fine but obviously something wasn’t right. Fuse box stopped over heating and blowing main fuse after I replaced. I was able to start bike with push button after replacing the RH switch assembly. I hadn’t done that in 25-30 years. High beam and Low beam change was a lot smoother. I’m just saying there may be intermittent connection issues that just looking at can’t catch, unless you are an electrical wiz like some on here. Replacing components until the issue goes away might be the only option at this point. Or you might want to reach out to Bodi on here. He seems very electronically knowledgeable.