On my 93xl the headlight switch is not working so I took it out and picked up a new one. The issue is, that it looks like the wiring has gotten hot at some point and began to bubble or melt? I don't want to throw a new switch at it if there is a more serious problem? I can plug the wire directly into the terminal and get headlights but again the wires get extremely warm. Anyone have any experience with this or ideas? Thanks for any input.

 

It's what they do. You can wire in relays to fix it.

 

x2, also check to make sure that you have the proper size fuse.

 

And check the headlight ground wires for connectivity