Regarding the amperage differences between the two bipolars, I swapped engines from one line to another and determined that it is the transformer and not a difference in the engines. I don't know why one throttle of the Z-4000 would put out more amperage (0.6 to 0.7 amps) vs. the other throttle (0.3 to 0.4 amps) while the engines are running; throttle one is mainline No. 1 and throttle 2 is mainline No. 2 - both are about the same length, number of switches, same number of wire drops. I tightened all connections on the terminal strips, none were that loose, so I don't think that is it.
Regarding the tachometer, it looks okay to me ~ the "reader" is about 1/8" from the flywheel. I took a couple of pictures and noticed a male wire plug that has no female counterpart - its the yellow one in the middle of the picture. Anyone know why this plug exists? It just hangs in the engine compartment.
Unless someone has a suggestion, I plan to continue to run both bipolars and lashup them up...perhaps I am only chasing gear variances due to manufacturing.