With all the clutch threads, and seeing some of the pics, has anyone every applied a thin layer of grease to the clutch plate? I see lots of them rusted to hell except where it engages. Could tiny rust particles be getting in there and causing issues? Rust gets between the air gap, clutch engages, slips slightly and rust does damage. The thin layer of white lithium grease would coat the plate. It may slip slightly the firsy go or so, but it will eventually wear off, but the surrounding grease will prevent corrosion.

or maybe its just early and the coffee hasn't kicked in yet.

I sprayed mine with corrosion x one time, didn't last long though. Actually a good coat of paint wouldn't be a bad idea neither. I guess they look at them like brake rotors, if it's used regularly, you wont have as much of an issue. If you had a friend that would powder coat would be good also. But with any coating, rust will start at the engagement surface and work it's way underneath anything you put on it. Or bake it and season it like a cast iron skillet

Use it more

My take on this constant clutch issue. Please understand that the PD is the best motor for me. Yet I have spoken to a number of techs from companies that make the mower clutches we use. This is the bottom line; PD is using clutches that aren't designed for what we are using them for even stock. The 5218-261 is made for a mower with tops 32hp and running at 3600 rpm. Not to mention that a mower clutch has less a load on it as a constant thing like moving our boats. In addition the mower clutch has a lot more cooling air passing it. No one likes more speed than me and if I were younger I'd probably be hitting the bottle (nitrous) to push the envelope.
It is too bad the market is so small that major companies wont spend the bucks on solving the problem. Just like PD tried with their larger clutch and they still burn up as I read here. A new design is in order and as I mentioned in the past, a spring clutch that the electromagnet for disengagement only, which would keep the heat build up to a minimum. They exist but not for the HP we want. Another thought is an old-school mechanical clutch (multi plate as in bikes) with a lever or pedal for disengagement.
Heat build up is whats killing the already under design clutch and as I reinstall my latest new one it is getting an attachment lug so I can install this
http://www.ebay.com/itm/142147088283?_t ... EBIDX%3AIT

I will set the temp alarm for around 200* and monitor what I see. As a last thought there are folks here that get many hours out of their clutches, all I can guess is they don't run them as hard as I do.

I will also note that alignment can make a big difference.

Couple of issues there.

1) Making absolutely certain that you are equal on all four corners. I realize that with the spacers that should not be an issue, but with the hydro reverse there is a washer that if it gets left out you will burn thru clutches. Ask me how I know. It looked fine, but when I put the caliper to it, it was off 1/16 of an inch. Only time I have ever had problems with the clutch.

2) Making sure when you set the motor back on, that you allow the motor and clutch to align them selves before you tighten things down. The tendency is to bolt everything down tight and then drop it on, but you do not want to do that. Let it find it's alignment and then bolt it down. Make sure you are level when you drop it on. PD has a process for doing this.

Just a hair off and you are burning you clutch up.

Banded, I know you have hrydro reverse and I would make sure you have that washer in there.

As to heat, maybe that is why we haven't had a lot of clutch issues. We Don't grind in the mud a lot. The occasional mud pie/hydrilla grind. Lot of impacts but not a lot of grinding.

Just throwing some thoughts out there...

I still don't understand how you guys go thru so many clutches, even if you are running modded motors.
I beat mine up in the cypress knees for 3 hrs this am driving like I wanted to break it while running traps. it's old, I never give the clutch a second thought. I figure i'll throw a rod before the clutch goes.
maybe yall are installing them wrong? I wish I could help because this is not normal.

^^^ x2^^^ the 04 is still running the original clutch as is the 08.

that sounds like a answer only a mechanic could give!!! lol