I initially thought the problem was caused by the fuel filter so I replaced the fuel filter in September 2018 but found it made no difference.
In December 2018, I removed the carburetor and cleaned it up but did not replace any of the components. Inside the fuel bowl, I found orange colored residue which I assumed to have been bad fuel. I reinstalled it with a new air filter but still had the same troubles.
In April 2019, I managed to get the mower to work a little by keeping it on choke. It would still die when I was going up a hill or over anything thick. However, I was able to mow a section of the property. In the process, I noticed the engine did not want to start with the key and it appeared the actual starter switch (made of plastic) was worn out.
In August 2019, I installed a new starter switch and found the mower would still not start using the switch. At this time, I noticed the starter solenoid was also cracked and would not work. I started it manually by bypassing the solenoid but it would not continue to run or allow the blades to be turned on without killing the engine.
September 7th, 2019 - I replaced all the fuel lines with 1/4" line, installed a new fuel filter, replaced the starter solenoid, drained the fuel tank, and then washed out the tank with B-12 before adding fresh fuel. I was then able to get the engine to start and it ran better. However, if I tried to turn on the mower blades it would die. It seems the fuel filter is not filling much at all with fuel (like at all).
September 21st, 2019 - This weekend I changed the oil and put on a new oil filter. I found a replacement gas cap which fit the tank and installed it, and then I started work on the fuel pump. The job was not bad but once I was done, I started it four times with starter fluid and it would not continue to run. I probably could have tried a few more times but I think something must be up with the carburetor. I hate to just keep throwing money at it but I don't know what is wrong and at this point, it seems it must be the carb as everything else has been replaced.
At this point, the time shown on the mower is 68.8 hours.
October 4th, 2019 - This weekend I rebuilt the carb by soaking it in B12 then replacing the float bowl, float bowl gaskets, needle, and each of the gaskets to install it. I plan to install it along with two new spark plugs this coming weekend. Hopefully, this will get it running as I've replaced the entire fuel system now minus the carb which has been rebuilt.
This time, the float bowl has a large number of black flakes inside. I'm not sure what this is but a guess is the it is part of the deteriorating fuel lines that I just replaced.
Parts Listing (Alphabetical Order)
Air Filter - Kawasaki 11013-7031
Fuel Filter - Kohler 25 050 22-S (currently using APE Racing replacement)
Fuel Hose - 1/4" Diameter
Fuel Pump - DR 49040-0769
Drive Belt - DR 221331
Oil Filter - Fram TG4967
Spark Plug - Champion RCJ-8Y
Starter Solenoid - QuickCar Products 50-430
