You usually use a resistor to pre-charge the capacitors, then make full connection without resistor. This will eliminate the spark.
Using proper connectors is important as well. If you use connectors with a small contact area during initial connection, you will form carbon and eventually create a resistor of sorts during the initial connection.
Castle says that the spark is "good", and to an extent, they are right as it lets you know that your capacitors are still good. If there is no spark, you cannot tell that your caps are good. This is one of the drawbacks of putting inrush limiters into the circuit.
Anyways, just got back. Same thing, tail is now a good 5 degrees at neutral, but the tail still wants to swing off to the right. I had to use about the same amount of correction as before, and this tells me that the gyro is "seeing" a constant rate of rotation to the right and it is trying to correct the motion by applying left rudder input, forcing me to counter the gyro input. I put my rate mode gyro setting at 50%, flipped it off, and the tail only needed minimum correction. The gyro is seeing motion that isn't there, and my guess is that it is vibration related.
As far as vibration is concerned, the helicopter seems to be pretty smooth, and I do not hear the telltale sound of poor blade tracking. I am a bit apprehensive of putting my braincase in line with the spinning rotor, so I am going to have to find out how to test this.
Anyways, time to add more vibration protection to the gyro and try again.