Okay, so I ran it down to the dealer this morning for him to take a look see. He was swamped with saw repairs and down a man, but agreed to check it out while I waited. He thought the melting was friction rubbing from air cover contact. He was a bit perplexed though that the air cover was super tight and didn't show any movement. His claimed Husky should have run the wire in from a different direction. His fix? "Keep an eye on it."
He checked out my pull start and agreed to fix it. I mentioned they had fixed it once before, that it was still under warranty and that I had actually paid for the parts before. He said "well, since you paid for it once before, I won't charge you today." At this point, I'm not sure what the Husqvarna warranty is supposed to cover or if it's worth a damn at all. Maybe it is just this dealer.
While I was waiting, I started to check out all the saws in for repair and their cards tied to each one. He was almost covered up with 372xp's BTW. Many looked to be pretty old and plenty ragged out. Lot's of logging here in this area. Lot's of "does not start." I noticed a 562xp sitting there with a "does not start easy/runs hot" written on the tag. I asked him about the Autotunes when he brought my saw back out and his response was "you don't want anything to do with those saws" and basically to stick with what I have. He sounded frustrated with the whole concept. I tried to get a little more out of him, but he kind of acted as if he'd already said too much. I like getting opinions from the shops actually having to repair them so that I know what to stay away from. User error on the Autotunes or design flaw? Not sure, but I think I'll stick with tried and true.
Interesting morning.