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Old 08-10-2014, 10:50 PM
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zx14 zx14 is offline
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Badboy diesel clutch issue

The clutch has two wires that run to it and I keep burning or melting the top wire where it plugs into the clutch. Wondering if anyone has ran onto this issue before. I always idle down for engaging the clutch blades. Wondering if it is because I also run the thicker and wider gator mulching blades. These are heavier then the oem blades. I replaced a clutch last season as the terminal broke inside the clutch and now I am already seeing it doing the same thing. Some reason this wire is getting very hot at the clutch.
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Old 08-11-2014, 07:59 AM
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Is there a short in one of the wires leading to the clutch?
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Old 08-11-2014, 10:50 AM
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Sounds like it could be a wire somewhere in the wiring harness shorting and causing extra heat to the clutch. You will have to find someone that is good at testing electronic and have him find it for you in the harness. Could take 10 minutes or 8 hours. It may be easier to buy a new wiring harness for $200 and do it your self if your dealer sucks... The clutch is one of the nicest ones in the market, we sell it for $299. If your mower is still under warranty, it should be covered no problem... Clutches are weird, I have some guys that blow through them, and some that never need replacing. I have one guy that runs grasshopper buy 4 in one year. He wouldn't let me check his out though, just kept coming in buying new ones. I bet his just needed the gap adjusted...
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  #4  
Old 08-11-2014, 11:18 AM
dieselss dieselss is online now
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Usually connectors burn up b/c there is to many amps flowing through them or improper solid connection. You said they burnt up before? Have you looked at the pins inside the plug?
Also ck your air gap as said. Might be half your issue right there
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Old 08-11-2014, 03:41 PM
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Tell me about this air gap please. Last year, it melted the connector so I had to run new connectors already. I spliced into the harness about 6 inches away from the clutch. No issues at splice, just hot at the clutch pins. The last clutch worked fine, it just lost the connection so it couldn't be excited anymore.

Last edited by zx14; 08-11-2014 at 03:50 PM.
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  #6  
Old 08-11-2014, 08:40 PM
dieselss dieselss is online now
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Ok. There has to be a space Inbetween the outter plate and the clutch material. There's 3 holes and 3 bolts. That's where you ck.the gap. Usually. .012-.013 ish
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Old 08-11-2014, 08:44 PM
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I didn't even know it was adjustable. It was one self contained unit I just replaced.
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Old 08-12-2014, 01:24 AM
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Make sure when you replace the clutch you replace the pigtail also. It has diodes in it that can short out. I also recommend doing the pto switch too when its electrical. Talking about extra 14 and 21 with a 300 part its the safest thing to do...
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Old 08-12-2014, 07:47 PM
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Thanks for the info/replies, fellas. I spoke w/badboy today and they said usually the replacing the clutch cured this melting problem. He suggested replacing the harness thinking it is making a bad connection somewhere up front possibly. There also are no diodes in the harness unless it is an injected model which mine is not. He then said a fuse would blow first if the switch was the culprit....
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