Looking for any help here. PD with modded kawi, nothing radical it runs well. I just shredded my 3 clutch in under 200 hrs use. First 2 were my fault, allowed grease from reverse gear and tower to get into the clutch. Like I said, my fault. Disassembled and cleaned tower and all components, reassembled with very light greasing, got 10 hrs on it, and shredded the straps yesterday. These are xtreme clutches, made for these motors, and I know there are guys out there with more HP than me, running them harder than I do that get good life out of them. I could live with 200 hrs, but this shit is ridiculous!
Any ideas? All torques and break in are in scope, so not sure what if anything I am doing wrong.

Usually I would be looking for poor power supply but since you broke the straps power supply probly isn't an issue. I would still check all wiring and connections just in case. Your idle rpm should be chill enough not to snap them when engaging. I realize I'm not much help on this one so... Following

Not many if any with more power. Lol

Dennis, my buddy mike went through the same thing. Those xtreme clutches can't handle the torque of the kawi is putting out. But, I "heard" that PD did have a "heavy duty" clutch now that is suppose to handle these engines better. Of course it's prob more, but if it works, then you save in long run. He was gonna call peck tomorrow and see what's the word.

I think you have something in a bind.

Only time we've had crazy clutch issues was when we were missing a washer on one of the tower bolts. My pops had a console and hydro reverse installed at pd while we had the powerhead doing some other work. Upon reassembly, there was some washer that's only used on units with hydro reverse that went missing. It wasn't enough difference to notice by eye, and it didn't seem like anything was weird when tightening up the bolts. After three clutches, PD had us take some measurements and sure enough, one corner was about an 1/8 of an inch off. Once the tower was square again, no more clutch issues.

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Yes there was a bigger clutch, but when I replace them now PD sends me a kit to convert back to the older style clutch. I don't think they are avail anymore

I dunno if it's more heavy duty, but the clutch I got when I put my new 40 briggs on is blue.

[/quote]Make sure everything is square. It's not just eating clutches because it has a kawasaki on it.

All spacers, washers, in place torques correct, and surfaces clean and flat. I talked to PD today, they have a clutch with heavier straps that warn is making, they're sending me one. Cross my fingers.


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I would take a measurement on all four corners (I did it with a caliper to be absolutely sure) just to be sure you are square.

There is also a very specific process for mounting everything back up and when you tighten everything down that PD recommends. Has to do with having the motor sitting back on the lower unit and letting it settle in and align itself before you tighten everything up.

Only issue with clutches burning up on 2 motors over almost 10 years now was with an out of alignment situation.

Been many folks running modded motors (probably some with more HP than yours) and no clutch issues....

Something is going on beyond just the motor having more power.

Took me a while to figure mine out-went thru 3 clutches within about 10 hours each before I did. (and numerous calls with PD about it)

yep, hydro

Thought I'd let you all know what happened with this. New clutch from PD, checked spacers all around and shimmed until I got it right. Got 5 trips on it now, and appears to have fixed the problem.
Thanks to those that pointed me in the right direction.

I believe you're just missing a washer. That was the case for us and blue. I guess as long as it's square, you should be good though.

Hope that fixes you up for good, or at least a few hundred hours.

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Yea, thats what I used. Used a caliper to measure then found some washers that created the correct thickness.

glad u got it working. I usually get at least 1000 hrs out of a clutch, sometimes over 2000. I usually get a new one when I have to do a lower unit swap or a towerhousing rebuild. getting pulled in ain't a fun time!!!

go run that thing!!!!!!