PM is not the way to go since the next guy might find his answer here.
The wire colors are shown as the plug sits. The red wire feeds the ignition switch and needs the 30 amp fuse. Best bet is eliminate that wire from the top of the start relay since that's the wire that corrodes and heats up. Go to Radio Shack and get a 270-1234 in line fuse holder. It's waterproof. Get a pack of 64-3040 ring terminals and use the middle sized one on one end of the fuze holder. Cut the plastic off and SOLDER it or it will just start doing the same thing in a different place. Cut the spade on the bike's RED wire off and solder that RED WIRE to the other end of the fuse holder. Take the top screw out of your DOGBONE and put the ring terminal there then screw it back in. That will get the heater away from the expensive relay.
Pop the green cap off the relay to expose the terminals. Clean the heck out of them with sandpaper and baking soda. Take the plug with the YELLOW/RED wire attached and if it's still good, plug it onto the left terminal closest to where the fuse was (see pic). The other wire that has two wires going to it GREEN/RED goes on the other terminal closest to where the fuse was. If either of these spades are corroded, replace them and SOLDER.
Put heat shrink on the spades all the way down (remember, your green protector is probably gone, but if not, put it back on) and put an extra empty spade on the terminal that once had the offending RED wire on it. That RED one was the wire that caused your plug to melt because it was always hot while the bike was turned on. The YELLOW/RED is only hot when you press the start button so it won't start grabbing oxygen from the air and corroding and heating up. Insulate the rest of the terminals and if you have some silicon calking, cover them. If you have some, spray some battery terminal gunk on the relay terminals.
I would have more and will have more in a coupla days. I'm going to head over to a friends to fix his melted plug and will document with pics. This will cost you some time and about $6 bucks instead of $80 for a new relay and even if you get that, you still have to deal with that fugly melted top plug.
(this post may be edited as I work through the process).
>FUSE HOLDER<>TERMIALS<>MORE INFO<
