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I had the exact issue you described a few months ago. Figured it was the floor dimmer as stated by several in this thread, but wasn't. I pulled the actual headlight switch out and removed all the wires. The main power feed was black and melted. Its the thicker red wire, possibly with white tracer. Either way, youll notice right away. Had to buy a new headlight switch and redo the power feed connector as it was melted so badly. I also did the relay upgrade and HIGHLY recommend it. Tons more light and no more placing the heavy load on the headlight switch.
