If it's not profitable to add a transaction, then it is time to stop mining completely.
Hmm. What if you already have a ton of transactions which will give you a lot in fees, but takes up the whole block? Then a big transaction with a small fee comes along. It wouldn't be profitable to add it, but you definitely should keep in mining for the reward...
It would only be un-profitable to add it if you removed higher paying transactions in order to fit the new transaction in the block. Since the question referred to a "greedy fill", it was already assumed that once the block was filled with higher paying blocks, no additional transactions would be added unless they payed a higher fee-per-byte than the transactions that would be removed. Furthermore, the question was "will it ever become profitable to add it later". That seemed to imply future blocks that aren't full, not the current full block.
The cost to mine a block does not increase with additional transactions, so each transaction increases revenue without increasing cost.
Yes, but only if there's extra space leftover in the block.
See my previous comment about "greedy fill" and "ever become profitable to add it later".
The cost to mine a block does not increase with additional transactions, so each transaction increases revenue without increasing cost.
You're not accounting for orphan risk.
Orphan risk is constant, and won't go up when you add new transactions.
Many people believe that orphan risk increases ever so slightly with a larger block. If you solve a block that is 1 MB in size, at the exact same moment that someone else solves a block that is 400 bytes in size (because they included less transactions in their block), then theoretically, their block might propagate through the network faster, and therefore more miners will be building on top of their block instead of yours. This additional hash power working on their block increases the risk that your block will be orphaned instead of theirs.
This increase in risk is so small, that it doesn't take much in fees to make it profitable to add additional transactions to your block. I suppose a really large transaction (in terms of bytes) that only paid a 1 satoshi fee *might* reduce profitability due to the increase in orphan rate, but if you a large pool and are well connected it might not.