It wasn't any of the problems we thought it was - valves, rings, gaskets, etc.
The injector on cylinder #1 was flooding the cylinder with gas, preventing ignition and seeping out the headers and flowing down the pipe.
It seems your headers don't seal until they are hot, allowing the excess gas to exceape.
On Thursday morning Adrenaline Motorcycles
picked the bike up for free (one of the perks of membership).
When they got it back to the shop Scott (the mechanic) checked it over and realized the gas didn't smell right, so he immediately drained the tank.
With some fresh gas it started and ran OK, so we** assumed it was just the bad gas and did the rest of the service it was booked in for.
Problems appeared when I wheeled Miss Jaffa out into the yard and was about to depart.
While warming it up Scott heard that it was running on only one cylinder, and then we saw gas pouring out of the headers, the junction of the pipes and out the exhaust.
We wheeled her back onto the hoist and opened her up for surgery
First we tested the spark plug - no problem there.
That is when we realized that the cylinder #1 was flooding.
Scott swapped injectors, expecting cylinder #2 to flood.
To our surprise, both cylinders ran fine, so we put her back together and I took her for a 30 mile / 50 km run
On Saturday I went for a 90 mile / 150 km ride and all seems normal, if anything slightly better than before. One thing we did during the service was balance the throttle bodies - they were significantly out. (We didn't do that at the 48,000 service because somebody had dropped their gauge the day before.)
I spent today getting the grime of the Alaska trip off the surface of Miss Jaffa, but anybody that removes the seat & tank will know that she has been on a long dusty ride.
I have spent the last week playing "what-if". I had decided that if it needed a new motor / top end and the cost was more than $1,500 I would buy a low km 2007 Versys and swap all my improvements over and part out everything else. Otherwise I would buy a 2013 ABS and take what I could. Luckily I didn't have to do either of those.
Total cost excluding the oil change was CAD$200 / USD$150.
I consider myself very lucky.
** I am very lucky that Adrenaline encourage owners into the workshop, get their hands dirty and to participate.