Catalytic converters are a part that wear's over time, they can still totally be intact and not offer any benefit in reducing emmissions CO and HC - I think the maximum life expectancy is around the 150000k mark. What you need to get is a Euro IV emmissions cat off like a BF XR6T. I would also try as has been suggested hotter plugs with a larger gap - at least 1.1mm and make sure the ignition timing is not overly advanced.