Well ohn is in travel and merriment mode in the US west. I will however give an answer. The fact that it has a spark when the batt terminal is connected, and not when it is disconnected indicates that the Voltage relay cutout points are likely to be welded closed from either sticking from old age --Probable-- or from an incorrectly installed battery then started. Either can cause sticking. I would pull the cover off of it and see if the heavy set of contacts in it are closed. They should not be. Gently seperate them and use a finger nail file to dress them smooth, Then use a folded dollar bill to wipe them clean while pushing them together. If when you test the spark on the terminals it no longer does it with the batt terminal attached to the reg. start it and see if it works. if then sparks when shut off. (not good) I would replace the regulator. (american Made only) best of luck, Jim
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