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Bio BBs generally don't perform as well as non-Bios, even when comparing within the same brand/weight (KA, MB, BBB, etc); the only ones I've found to be good performers are the Green Devil bios which I'll be testing more thoroughly this summer, but currently they're the only bios I'd consider using.
You're also getting virtually no tangible gains going from 380 to 410 fps: you'd be lucky to get a measurable 3-5 feet more out of it. 400 fps is a limit, not a goal. So it effectively sounds like you went from a setup you described as "fantastic" and threw it out the window for nothing except more stress on your mechbox and decreased battery life.
My advice to you is go back to the old setup: when you have something good, don't mess with it.
That being said, I question how "fantastic" the range and accuracy were if you were using .25g BBs. Go to heavier weights (.28, .30) if you want to increase range/accuracy. Your BBs curving upward is a sign of too much hop-up; pulling to the sides [consistently] something is misaligned, maybe you need a better spacer; going off in random directions between shots, could be inaccurate barrel, crappy BBs, too light a BB, etc.
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