headlight mod

[limax2]

I presume the reflector has to be earthed against something?

I think not. The earth for the bulbs is through the black wires, eventually to some point on the frame. sounds like you might have a loose connection at the bulb that makes contact when you move it. Not on the Fazer but I once had a broken wire that was still held in position by the insulation, so watch for that as well. That made intermittent contact.