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So when side post cables touch the battery should I expect a spark every time?
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Not sure what you mean here.......if you ever disconnect a battery, you always disconnect the neg terminal first and then the positive.....when you go to re-connect the battery, you connect the positive first, and then the negative......
If you are connecting the negtive terminal and the wrench slips and touch the positive terminal/cable, yes you will get a huge spark because you are shorting the battery out.....
After you hook up the positive cable, when you initially connect the negative cable, there will be a small spark, as brcidd said, because modules are waking up causing current(spark) to flow....