Small Engines (Lawn Mowers, etc.): ELECTRICAL PROBLEM, twin cylinder engine, electric clutch

Question
I have a Huskee (MTD) 20 hp riding mower with a 46-inch deck and an electric clutch on the blade drive.  Unit is 6+ years old and has given minimal problems over its life.  Two years ago, blade drive suddenly stopped while mowing.  Isolated problem to pto switch and replaced switch.  Last week, blades stopped once again. Checked system and found switch bad once again.  Noticed that clutch was VERY HOT to touch.  Replaced switch again and unit worked for one hour and burned up switch again.  Plastic around one wire in plug where pto switch attaches was deformed as if it had gotten too hot.  Clutch once again very hot.  Any ideas?  (20 HP B/S twin cylinder engine does not seem to have problem).  Thanks for your help.

Answer
I would first check with a Huskee dealer to see if there is a warranty issue with PTO switches for your particular model.  Otherwise, things I've seen cause problems with an electric clutch are an improper gap (& clutch alignment) or a dragging blade brake on the cutting deck.  You will notice on the clutch there are three spring loaded adjustment nuts.  These are there so you can adjust an even and correct gap on the clutch.  Here is a link to explain an electric clutch operation, including recommended air gap setting and amperage draw (which could be your problem):  http://www.warnernet.com/pdf/819-0458_P-1097-6.pdf

If the clutch checks out, check for dragging blade brake(s) on the cutting deck that may be causing the clutch to heat up and slip.  Hope this helps.