There shouldn't be a rubber tip on the needle valve, well at least I've not seen one with a rubber tip. There is a rubber seal in the seat though.
I'm assuming you bought a carb repair kit when you replaced all the innards ?
Did you replace the entire needle valve assembly i.e. seat, copper washer below, needle valve, lever, spring etc... ?
Did you also replace the diaphragm and gaskets while you were at it ?
Did you make sure the carb was surgically clean [and I mean absolutely clean] when you fitted the new parts ?
Do you have an in-line fuel filter to prevent any dirt in the fuel reaching the carb ?
Did you set the pop-off pressure on the carb ?
Here are a couple of helpful sites on Tillotson carbs for you.
http://www.aerocorsair.com/id27.htm
http://www.lazair.com/HL.htm
In all the time I raced 100cc, I always had more than one carb [usually dozens actually] when I went out with the kart. If there was trouble along the lines you're explaining, I'd swap the carb as taking one to pieces trackside is not to be advised.
Hope this helps.
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