Originally Posted by Stoney

You have just discovered what happens when you exceed the rated capacity of the wire and connector.

You should replace the connector with a HD type designed for double the wattage of the std lamps (30 amp rating) upgrade the stock wiring to 12 ga minimum (10 would be better).

Basic deal is you fried the connector and or the wiring and or the fuse/fuselink or the relay or any 2,3 or all 4.

Start with the headlamp wiring at the connector then the fuse, then the relay.