I installed one yesterday and love it so far. Haven't ridden it yet, but it was VERY easy to start and the throttle effort was reduced by 50%. Overall win if you ask me.
could be condensation. warm it up enough to smell the exhaust: should the exhaust smell normal it's probably condensation, should it smell sweet it antifreeze in your exhaust.
Die-over, tap-through.
that said, you may be better off with a thread file. They usually accommodate 8 different pitches, and that would cover damn near any thread on the whole bike.