Last stupid question (maybe not). Was the correct plug in the box?
Assuming that the plug and the threads and the washer are in place and sealing.
And assuming that as soon as the engine does start that the metal in that part of the head is expanding and sealing the cylinder.
Then the thing that would worry me... Does the plug screw into a steel sleeve in an Aluminium alloy head...
If so, is the fit of that steel sleeve still good? It's an ugly picture to even think of...
I wonder if one could put in a different/recommended plug, leave the kill-switch in the off position, turn the motor and listen for 'leaking air' on compression.
Even replace the plug with an equivalent nut...
I only know the Avenger, so forgive this question... Is the sound not coming from the head gasket area?
Grumble... Should have thought of this earlier. Is the exhaust close enough for the sound to be coming from there. My ZZR 600 did that once after a exhaust repair. The gap eventually closed by itself. I remember reading it was not uncommon and that carbon eventually closed the gap.
By now I would have been plotting to kill a wrench-monkey, just to get over the frustration...