I’m new around here as well, but from other vehicles, if electrical insulation 
melts, it usually means there is a short right where the damage is found. If 
you had an issue elsewhere in the system that causes over-current, you’d either 
have a fuse pop or you’d see melting elsewhere. You found melting at the same 
spot twice, so that’s where your cause is, nowhere else. It’s most likely crud, 
stray strands, or exposed wires that are moved together, that shortens the 
circuit right there, which creates the heat that damaged the wires or connector.

Holger 

> On Feb 22, 2019, at 6:48 AM, Final Twist <[email protected]> 
> wrote:
> 
> Are bad connections the only possible cause of this happening?  Does anyone 
> know what the other 3 wires do in the connector?  I can't read the really 
> complex wiring diagrams for the motorcycle 

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