Hitch,
Regarding fonts... All rendered fine on the Fire HD6 before updates sent to KDP within the last week. None were extra-bold as I'm seeing now. They are the same fonts that were in previous editions.
My primary concern right now is why the books have auto-hyphenation, but I'll also address the font issues once I hear back from KDP.
I've had the Fire HD6 since late November 2014. I don't recall if I checked my e-books right away after that, but I did look at them on the Fire right before making the recent changes. Every book was fine on the Fire HD6 then.
We didn't have KF8 when I started publishing. When that became available, I updated the existing books to take advantage of that. I've published several more since then. I have two cascading style sheets, one for mobi and the other KF8, and use media queries within the HTML. Never had any problems with that, and nothing's changed on my end in that regard.
For my first book, I exported filtered HTML from Word 2007-->fixed the HTML/created CSS, OPF, and NCX by hand/created the epub manually-->Kindlegen. Now, I copy the text from Word, paste into word2cleanhtml.com-->fix what I need to in Sigil-->command-line Kindlegen. These are not brand-new books I've recently uploaded; they're revisions to books previously published using those methods, without any problems before now.
Since the first book was only mobi, I tested then using my Kindle Keyboard. When KF8 came into being, I also tested on my Android tablet using the Kindle app. And now I check on the Fire HD6, too. Of course, I also preview the books at KDP before hitting the publish button. Everything looks fine there, even now...no extra-bold fonts, full justification, and no auto-hyphenation. I don't think their previewer is really accurate, though.
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....you THINK it's only for the Fire 6", because you have nothing else upon which to test, is that right?
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That's correct. The books look fine, even now, on my Kindle Keyboard (mobi) and 10" Android tablet (KF8). I only have the Fire HD6. That's where I see the problems--and only in the downloaded sample or purchased book. The sideloaded book from KDP, which I download from KDP after publication, looks fine on all my devices,
including HD6. No one has said whether they see these problems in my books on their larger Fire HD/HDX tablets or on the KF8 Kindles. I'd like to know.
I'll try some of your suggestions if KDP confirms that the problem is on my end. As I said earlier, I only see the problems on my Fire HD6 after the books are
published and available to purchase. I don't want to interfere with KDP's investigation by uploading anything new right now.
Thanks again!