"on the left side headlight it looks like the pig tale got a little hot and
> has some black plastic but still makes contact and is not very bad"

This may or may not be related to your situation, Kevin.

I've also installed relays and use 80/100 bulbs. My left connector also
melts. I've replaced it twice and have now been looking for a beefier one to
handle the amount of current.

Another "fix" for this is to switch back to 55w bulbs there. Which I think
is where I'm headed. I think the extra current to the headlights the relays
allow will be enough improvement over stock through-the-switch flow, to get
the light I'm looking for.

For heavier harnesses, look here: http://www.hioutputbulbs.com/compt.htm

bob
'87 Westy Syncro