Hey Mark. You mentioned 'unchecking the modules' in devices. Are these external sound modules? Do you use a different midi interface for your live performance PC to the one you used to create the project? You need to double check that there are no hidden midi tracks looking for an external midi output. Even archived midi tracks that are missing external midi hardware will do this.
Just a tip - you dont need to delete any unused/bounced midi tracks. If you load any vst synth and set your midi outputs to that synth, you can then disconnect the synth in the synth Rack and archive the midi tracks. From then on they are using no resources, and you can load the project on any system - even if it doesn't have the disconnected vst synth installed. They will never bother you again until you need them. Unlike external midi ports, Sonar will ignore disconnected synths and the midi tracks that feed them.