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Greg, I saw what caused the pop when I removed the alternator. The bare part of one of the wires had touched the case of the alternator. I taped it up and fixed that.

Thanks for the help. I had a loud pop and spark when hooking up the battery cables about 6 months ago after I installed my rebuilt passenger side alternator. I think I started connecting the front battery first and the pop came when I attached the positve lead. I could not understand how this...

Is there a proper order to connect or disconnect the batteries on a M1009. I usually disconnect the positive first and connect the positive last, but with two batteries connected is this right?