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GT235 Issues

6K views 16 replies 10 participants last post by  DaBomb6988 
#1 ·
First problem. The left spark plug will not thread all the way in. Looked at the the threads and there looks to be carbon buildup from the PO not having the plug seated all the way in. Could be cross threaded. What's the best way to fix it? Buy a tap and retap the hole? I tried a lil PB Blaster and working the old plug in and out and it feels like it hits a wall. So I'm thinking it's cross threaded.

Second Problem. The battery light is on constantly. The battery is good and it's charging when running. Is there a way test the discharge sensor and then voltage regulator?
 
#2 ·
As for the hole, you could try a spark plug hole thread chaser, they sell them at auto parts stores, one side 14, the other 18mm. You should have the head off so shavings don't drop in there, but I won't tell if you don't. Definitely, do it with the piston at TDC compression stroke and have a running shop vac next to the tool while you're screwing it in and backing it out to break chips. The best repair would be to remove the head and use a Helicoil Hard to justify buying the whole kit for just one whole, so take it to an auto parts store that has machine shop services if the first version doesnt work. As for the battery light, I'll pass the torch to someone who knows this particular machine.
 
#3 ·
Second Problem. The battery light is on constantly. The battery is good and it's charging when running. Is there a way test the discharge sensor and then voltage regulator?
I'd kinda like to know this, too. My '02 GT235 does this, and has been for the last 4-5 years, but it can sit for a month and still start with a little choke, and it runs fine afterwards, so I haven't worried about it.
 
#5 ·
I think I might try the thread chaser. If it's just carbon build up it should go through pretty easy otherwise I'm going to just leave it the way it is.

Can it overcharge? The reason I ask is after an hour of mowing I notice the battery sometimes is leaking out of the vent.
 
#9 ·
Last 235 I bought, a bolt was in the spark plug hole. Felt like a 10hp single cylinder. Think it had a broke rod.
 
#11 ·
So I had a chance to tinker with it this weekend. The thread chaser w/grease worked great! I found the plug was cross threaded and at an angle so I couldn't use the thread chaser. So I took a chance and got a little piece of the original threads and cleaned them up and was able get it back working.

Now for the battery light issue. When the light is on, whether at idle or WOT, I'm getting 14.62+ volts which seems high. When the light shuts off I'm getting around 14.4 volts.
 
#12 ·
I had a GT 235 with the batt light problem and for the grand sum of $19 replaced the VR and the problem was solved. As for the thread problems good advice from all. Then thread chaser and grease are the best and least costly of your options. I would imagine in the near future you will need to helicoil that hole. You basically do the same thing you did with the chaser except you use the 14mm tap that comes in the kit along with the proper coil. Same grease trick and cylinder at TDC with a shop vac and small hose to fit in the spark plug hole. Follow the directions faithfully and use the red lock glue AFTER you have cleaned out the new threads with carb cleaner. Allow the glue to set for at least 24 hours or longer and then you are all set with plug threads that are better than the OEM. BTW, my GT 235 had the B&S engine in it so if you have the Kawa you might have to pay more for the VR.
 
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