Help, Alternator Hook up for the /6, I thought I had it right! - ZAP, ZAP.. Options

[DougC]

I have a problem where I get a major spark when attaching the battery cables to the battery. Clay Perrine pointed out to me that it's the heavy RED wire that's attached to the Starter (same place as the battery cable) and runs up to the back of the alternator. Clay suggested that this red wire was hooked to the wrong post on the altenator. OK, I removed the complete CIS injection unit and peeled back the engine shoud. The wires were hooked up to the alternator like in Wayne Dempsy's book, the pictures I took upon disassembly were lost so I had to use the book for this. I'm using a newly rebuilt Marchall alt. with external regulator. Here's a breakdown of how I have it wired:

(posts are clockwise from the top)
"+G1" or "+61" = blue wire
"B+" = Red wires [one thick, one thinner]
"another B+" = short ground strap from engine case
"DF" = black wire with spade end
"D-" = 3 small brown wires
"D." = un-used

Where have I gone wrong?

Doug C

[DougC]

Jim, I moved the ground to the fan frame body just to see if the same sparks flew when attaching to the battery and the same thing happened. I did not have the plastic piece on the back of the alternator though, it may insulate the ground or something..ya think? Could I have fried the red wire and rendered it inoperable, I did see a small puff of smoke at the alternator then touching the cables to the battery.

Doug C