Crazy electrical problem!

[motomartin]

Help,
My RE5 has a strange electrical problem possibly a grounding issue.
I had the key in the ignition in the on position, another key was attached to the key in the ignition with a small metal ring. The key not in the ignition was touching the handlebars and sparking (arcing). The small ring holding the keys together quickly melted stopping the arcing and the key fell to the floor. No fuses burnt out or anything, what do you think is causing this?

Also the starter is turning slowly. The starter solenoid gets hot where the positive lead from the battery attaches and the negative battery lead gets warm/hot also when I crank the bike over. I just took apart the starter motor and cleaned it - no difference. Any ideas?

[snowrench]

Simply put, there is a difference in potential between your switch and the handlebar. The switch is mounted in a plastic bracket which insulates it from the chassis. If the switch has an internal short, it can't go to ground until something jumpers to ground (your keyring.) Put the leads of a voltmeter between your switch housing and the chassis and you'll probably find voltage, and apparently a source of current that isn't very fused. The handlebars are at ground potential, so I would say your switch is bad. If you can continue to isolate it from ground it may work for years. It also may be that a wire or connection is bare and is energizing it, and that can be remedied easily.....

[motomartin]

Dec 3, 2011 21:05:59 GMT -5 snowrench said:

Simply put, there is a difference in potential between your switch and the handlebar. The switch is mounted in a plastic bracket which insulates it from the chassis. If the switch has an internal short, it can't go to ground until something jumpers to ground (your keyring.) Put the leads of a voltmeter between your switch housing and the chassis and you'll probably find voltage, and apparently a source of current that isn't very fused. The handlebars are at ground potential, so I would say your switch is bad. If you can continue to isolate it from ground it may work for years. It also may be that a wire or connection is bare and is energizing it, and that can be remedied easily.....

Thanks for your reply, I will take a look at the ignition switch wiring.

[motomartin]

My problems are getting worse. I took the ignition assembly off and taped up where I thought it may be contacting the triple clamps, when I reassembled and turned the key several wires started smoking and now several of the wires have melted.

[snowrench]

On my Re5's there is a in line fuse on the wire from the positive terminal that feeds the entire bike aside from the starter. You should probably have one of those to protect you during shorts.

[motomartin]

Yeah, it seems like it needs some protection. I'll add a fuse like you said.