Great job on the write up! I had the same issue with our 2009 Rap 90. Ended up ordering a new pilot jet and had a machinist friend bore the jet to .35mm, up from the stock .32mm. Starts and runs much better but if the jet gets the slightest blockage, it is hard to start and will not idle. We have a Polaris Outlaw 90 that has the exact same problem. The pilot is so small that they partially block with varnish and are very tough to clean out. I think I am going to open the pilot up a little more to .37mm. We definitely run the carb out of fuel after each run. Looking forward to watching your videos. Oh, the first time I removed the carb, I didn't remove the heater and rotated the carb and guess what, broke the heater. Learned the hard way.