Clutch will not engage

[tfenby]

My PTO is not engaging. I purchased a new clutch pig tail and a PTO switch but this was not the problem. The dealer said it is most likely the clutch. The machine is an 06 Super Z XR760 with a Kohler engine with low hours. I did cut allot of long grass this summer which could have burned out the clutch. It worked fine the day before then when I went to start the machine the next time it started for a half second (Weakly) then quit. Now there is nothing. You would think you would hear something or the clutch would give some indication of slipping. The only thing I did not replace or check out was the seat safety PTO switch.

I'm looking for guidance on what to do next. I'm a do it yourself mechanic and would like to fix this myself. Does anyone have any suggestions to diagnose the problem. Is there anyway I can check if the clutch is magnetizing and trying to engage? Can you disconnect the cable and check if it getting power? Has anyone had problems with the seat PTO safety switch. I know my big butt is putting plenty of pressure on it.

Lastly, if it is the clutch, is this a complicated replacement? You can buy a clutch replacement for $250 on line but the dealer would charge me $400 to replace it. Money is tight and I would rather do it myself but if this can screw my machine up then I will gladly take it in. Your thoughts?

[mowerconsultant]

This could be a relay or wiring still.
The seat switch is fine likely, if you can sit in the seat and pull in the drive levers and get up and the unit shuts down then the switch is fine.
I would really let the dealer look at the unit to get this taken care of, it could be wiring or it could be the clutch.
How many hours are on the unit?

[Ruben Rocha]

Stick a heavy object on the seat. Fire it up and check with a volt meter to see if you have 12vdc to the clutch. the pig tail should be accessible from the top if you pull it up through the hole in the frame.

[tfenby]

Good suggestions. I'm still curious if anyone has replaced a clutch by themselves. There seems to be one bolt holding it together. I'm going to grab my volt meter and do some more investigation. The seat diagnostic is simple and thank you Rocha for the suggestion.

[Sharpcut 1]

There are 6 relays under the dash, and also a fuse for the clutch. the clutch usually does'nt just go out, unless the bolt backed out of the crankshaft and dropped, or you hit something and it stoppedsuddenly. Need to do more electrical diagnostics,. Run a set of jumper wires from battery to clutch, unplug pigtail, and hook one wire (RED) to Positive, black to negative. If it clicks, it means clutch is good.

[MOHUSTLER]

To replace the clutch its easy if the clutch comes off easily. Sometimes they can fight you comming off and back on again. You will probably need a gear puller to get it off. And a steady hand to get it back on. But it can be done by yourself. Just make sure you have the mower good and secured before you get under it. You will have to do some pulling and beating and banging to get it off.

[SunState Lawn Care inc]

Look under the seat and see if the fuse is blown(if it has one there my toros do) if it is and it blows another one the clutch is most likely bad.

[Sharpcut 1]

Also, there was a relay update from macines from 05-07. If yours is an 06, has the relay update been done?? It was covered under warranty, call the dealer with model and serial # and they can check if your machine falls under the update. My gut feeling is still an electrical problem.

John
Svc. Mgr. Pro-mower and Snow equipment
Warren, MI

[jknowles4]

I had the same thing happen to the same machine. There are 3 wires running to the back of the motor. You can see them by looking at the back of the machine. One of them had vibrated off and this stopped the clutch from engaging. Check there.

[tfenby]

I ended up putting a weight on the seat and pulled the pig tail going to the clutch. I verified current was going to the clutch and it would not engage. While it was running I pluged it into the clutch. Absolutely nothing. No clicks or vibrations came from the clutch.

As far as I could tell there is only one wire going to the clutch . Logic would tell you that it should engage since it is getting charge but it does not. The center bolt is spinning fine and I confirmed the belts are not slipping. jknow you mentioned other wires that may have come off but I did not see anything. I don't see how any other wires could affect the clutch other than the pig tail at the bottom. Maybe I'm wrong. So after a little more diagnosis does the group agree the clutch is bad? I would have liked to hear it grinding or tring to engage but maybe that's how they fail.

[SunState Lawn Care inc]

MIne has one plug with 2 wires I just dealt with this last week. Mine is a Toro though so could be different. One of the wires in the plug has slipped out and wasn't making contact..... my plastic plug had crystalized and broke so I ran the other plug straight to the connector and plugged the plastic that was left to the other side of the plug. Check and see if one of the wires has slipped down in the bigger plug. Use a test light to see if there is power going to one side of the plug back at the clutch if so it is in the clutch most likely.