Al,
I have not had the problems you mention in your 9-10July note. However, I have not tried to check some of the things you report such as accuracy of the thermometer. My gas mileage (from the dash meter which I checked thru 2 tankfuls the old fashioned way with a calculator and it seems within + or - 1/2mpg) has been showing about 15 around town (small town) and about 18 on the highway. Interestingly, I live at about 3200 ft (that gauge IS accurate checked against an aircraft altimeter) and it is 50 miles to sea level. I get 23 mpg going down the hill and only 15 coming back up!
Different subject. I learned that if you want a real mellow sound (about like the Borla on my GS400) you can actually just remove the muffler and replace it with a straight piece of pipe. Seems the cat converters in conjunction with the resonator at the rear function very well as a muffler. No discernible increase in power, however.