This probably needs some careful investigation. If you can only work out how to harness this outrageous power increase you could be onto something big here. Think about the aftermarket possibilities and the revenue stream you'll generate. You'll probably have to think about moving into a bigger house & consider hired service.
But maybe I'm getting a bit ahead of myself.
Only thing I can think of (after thinking I bet the throttle cable is hooking up a few times whilst reading, but I believe you've checked now you mentioned it so many times) is perhaps the throttle slide. My EC200 never had such problems & neither did my KDX.
But it (KDX) did have a PWK carb & the slide on that was badly worn so I replaced it thinking it was only a matter of time before it hung up. Looked like a 1/2 moon shape worn into the slide from rattle at idle I guess.
Lean revving usually only occurs under no load. Turn the gas off & run the bike & it will rev a little high, but not crazy, If it was being ridden it would just die under load.
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