Small Engines (Lawn Mowers, etc.): John Deere 265 Kawaski engine problem, john deere 265, fuel tank cap

Question
John,
7/25/06 I asked you about a John Deere 265 with Kawasaki engine problems.  I had already experienced problems with the fuel tank cap. I stopped that by drilling a larger hole in the top (clear section) of the cap and relieving the air vent hole.  I removed the carb. It was very clean, no varnish, no trash, no apparent water damage. The float was set as you recommended, level when turned with float on top. I removed the fuel line from carb to fuel pump, it was clear and clean. I removed the fuel pump. Checked the vacumn line from engine to pump it also checked out. I removed fuel line to filter, filter, line from filter to cut-off valve, removed cut-off valve. All of these checked out OK.  I then removed the seat and rear deck cover to access the fuel tank. Fuel line from cut-off valve to fuel tank checked good.  I removed the tank. Removed the fuel pick up tube from tank. I had trouble removing the fuel pick up tube because it was so corroded/oxidized on the outside instead of being 1/4" OD it was about 5/8" OD.  The Pick up fitting is brass while the tube into the tank is *#@*&*> steel.  I cleaned it with wire brush and sand paper. If I blew through the Fuel pick up tube like blowing back into the tank it was clear, when I sucked on the tube it would go "bonk" like a check valve was slamming shut.  I took a long wire and removed what looked like the cotton ball from a Q-Tip. It was rusty looking and could have just been a build up of lint, etc. from the gas. After I cleaned tube inside and out when I blew through it there seemed to be some leakage. Under water there appeared several small air leaks. Of course the dealer didn't have the part in stock.  I bored the old steel tube from the fitting and soldered a 1/4" copper tube in place.  I hope there is not something in gasoline that will eat up the copper.  I don't know why JD would use plain steel instead of something that would resist oxidation.  It takes a lot of time and work to remove/replace the fuel tank.  I also replaced the fuel pump vacumn tube with a vinyl pneumatic type hose as I was somewhat skeptical of the braid armored rubber hose.  After I primed the engine it started and ran very well. I mowed for about 15 minutes and everything seemed good.  Thank you for your help. It seemed to me that you were certain it was a fuel problem. So I thought the best tack was work back to the source of fuel. I guess that when the mower was running good and when I made a sharp turn or went up or down a hill possibly the gas fell below the little holes in the tube allowing air to enter the system. Hence applying the choke helped alleviate a sometimes intermittent problem.  Thanks again for you support.
James  

Answer
 Hello James:

 No Worries: Im Glad you Got it Going. Thanks for the Input. I will Add the Pickup Tube to my List of Causes. From the Way you Described the Problem; it had to be Fuel Related. Remember Us at All Experts when you have a Problem. May All Your Mechanical Problems Be SMALL ONES. Happy Mowing. Thanks for the Email.

 Good Luck and Best Wishes

 Respectfully

 John