SOLVED: CA3, HiGo, Key Return ? Where does the key switch connect to?

No, there shouldnt be at all if the motor is not running, no current flowing there should be no sparks
 
The sparking most people get is from filling the controller capacitors. If they were completely discharged (normal when the bike has no battery plugged in for a while, a few minutes to a few hours), then you can certainly get a spark when plugging in a battery, whether the controller is "on" or not, if main power is connected to it.

To avoid this, create a precharge circuit. There are dozens, if not hundreds, of threads about that, under precharge, pre charge, antispark, anti spark, etc., with many possible methods.
 
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