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EVO Softails are notorious for bad frame grounds & regulator grounds just as an FYI.
I do tend to think if you had a bare wire shorting out a fuse would blow. On that vintage, poor connections and ground problems are very common. Have you looked to see what is clicking? I'm thinking you could look while hitting the headlight, moving front suspension - simulating some movement or vibration.
Just as an FYI for the future, if you ever have a melted clutch cable, that's a sure sign that you have lost a ground and are grounding through the clutch cable.
It's possible your bike has thermal cutouts on various electrical circuits, instead of fuses, which may explain the clicking. One of those is probably cutting out your headlight due, as suggested, to a fault somewhere. Have you changed handlebars recently, or opened the handlebar switches for some reason? It is very easy to trap and damage a wire, which could be the cause. In any event trace your headlight wiring looking for damage, bad ground, etc. Your electrical problem is most likely a mechanical one, which should be pretty easy to spot. You could alternatively use a multimeter to check electrical continuity on your headlight wiring.
I was not thinking of a circuit breaker other than the main and was thinking fuses. If that is the case and there is one inline with the headlight, Dan could be on the money.
Thanks for the information! I bought this bike about 2 years ago to tinker around with. Got a fantastic deal on it so I couldn't pass it up. I have not changed the handlebars. I did put a new tail light assembly on it. Back end of electricals seem to be working fine. I am about to upgrade to an LED headlight while I'm working on this issue. Sorry for my late response, was a beautiful day here in NC and had to get some wind therapy in. My daily is a 2016 Electra Gluide Ultra Classic.
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