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I measured several here were all 74mm. No other reports of issues with that batch or any with this issue, so not sure what happened here. The one you have is 75mm?

Thanks for the great review Tim  . After we started selling those coils, guys kept calling about installation, so we put the kit together. It looks like there's plenty of room there, but its kind of tight and there just wasn't a simply way to do it. And the Dyna coils have been rock solid, don't think I've ever had a warranty claim on them. Thanks so much

you're fine, they just don't want the rotor to get damaged with a claw puller. The rubber strap wrench is fine. spanner wrench, penny in the gears, folded up towel, whatever holds it without damaging it is fine. I use a spanner wrench.

Thinking of you down here in Texas today Dennis! Godspeed!

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Tariffs on the RD Vape igntions are 52.5% $799 retail now. This is due to the high copper content of the generator and wiriing.

This is the worst year we've ever had, costs up 25%, sales down 25%, endless supply chain disruptions/delays and additional costs. The broader mc industry is in shambles, show room traffic down 40%, inventory glut, interest rates up, kids not really interested in bikes. Good news is it's a great time to buy a new bike, buyer's market.

one tooth on the rear makes marginal difference, the 39's that are commercially available are much cheaper, are steel and will last longer.

The yellow wire (ac) energizes the stock daytona headlight relay and comes from the original stator. Just run switched 12V dc (brown wires all over the bike) to it instead of the yellow wire. Will function normally as it does with the stock ignition.

Have you loaded a flat curve and shot it with a timing light?  Where did you install the rotor timing wise and did you update same in the zeel box for your static timing? This is always step 1 to make sure you have control of the curve. For clocking of the rotor, check your highest point in the curve you're running and make sure the rotor carries at least that much advance.

Nice job on the bike! Look'n good! 

A lot of guys run the 4ah scooter/alarm batteries that connect with spades. They seem to hold up well in a dormant state, which works well with RD's that spend most of their life sitting in the garage. And just let them sit in the bike, no charger. My experience with other typical motorcycle batteries is they all suck and you should plan on replacing them every year or two, maybe 3. Some guys swear by Yuasa but I don't find them to be any better than generic batteries and the Yuasa's have quite a premium price. Like tires and premix or the pump, there's no shortage of opinions about batteries.   

The YTX5L-BS will fit in the stock rd battery box, we've sold them for years. It's a bit narrower but you can block it up with some foam.  I don't think it's going to help with plug fouling, what heat range plugs are you running?

They also can lose efficiency when they age due to brush dust / grime on the contact rings and corrosion of bullets/connectors, loose connections. Gets dirty in there after a half century and brass connectors oxidize. Some contact cleaner on the rings and replacing old connections can help. I've had bikes come in that would only flash the signals if revved, after some good old-fashioned maintenance and a new harness, they'll flash with just the key on. Often mis-diagnosed as a bad flasher relay. 

AI says

Motorcycle generator connections are crucial for maintaining a reliable electrical system, but they can be prone to oxidation and corrosion over time. This can lead to poor conductivity, voltage drops, or even electrical failures. To prevent these issues, here are some tips:

Inspect Regularly: Check the connections for signs of oxidation or corrosion. Look for discoloration, buildup, or loose connections.

Clean Thoroughly: Use isopropyl alcohol or a contact cleaner to remove any oxidation. A small brush can help with stubborn spots.

Apply Dielectric Grease: After cleaning, apply a thin layer of dielectric grease to protect the connections from moisture and oxidation.

Secure Connections: Ensure all connections are tight and properly seated to avoid arcing or further damage.

Protect from Elements: If possible, shield the generator and its connections from water, dirt, and other contaminants.

These work great, plug and play.

https://www.economycycle.com/shop/yamaha-rd250350400r5ds6ds7-parts/electrical-ignitions-lighting/electrical-parts-and-related/regulator-rectifiers/yamaha-rd350-rd250-all-regulator-rectifier/