that sounds, that you slowly find the way to finish this problem...
question: it snows and rains also inside your garage, if you want to make the pics??
.... the kawasaki-doctor-team need no pro-pics to see the bike with the wrong exhaust and details of your fitting problems with the cr500-pipe .
...big bored carbs like your 40mm pwk or bigger are used for more airflow which makes sure, that the bike runs well in higher rpmīs like its needed for example in highspeed-runs.
for use on small mx-tracks or wood-riding, where is much power from bottom needed are smaller carbs like the stock 39mm or a 38mm in use on the k5.