Hi frob,
Just a few questions first-
1. Does the amp sound/behave exactly as it used to when in Distortion Boost mode?
2. When you say "90% less output" in clean mode, what type of "less" is it- less guitar sound with more background noise, or just less guitar level with no noise- as if the volume has been turned down?
3. When in clean mode, does the "Top Boost" make any difference to the sound, and can you hear the bacground "hiss" increase/decrease whilst switching it?
4. When you switch from clean to distortion, can you hear the relay click?
If you look at the above schematic, you can see that the input signal from the guitar is split 2 ways at the relay. The normally-closed contact (the contact connected to the common terminal when no power is applied to the relay) connects directly into the preamp. This is the clean channel. The other relay contact, the Normally-Open contact, goes to the Distortion Boost circuit. So when a voltage is applied to the relay, the guitar signal is connected to the distortion booster circuit, and the output of the ditortion circuit goes to the clean preamp circuit.
What Gus means is that when a contact in a relay becomes oxidised (due to age, humidity, lack of use etc) it has a higher resistance. If this resistance becomes too large, it stops the audio signal passing or becomes intermittent. Often just "working" the relay (switching it on-off quickly for a few minutes- make sure volume of amp is down!) will budge the oxide.
Small signal relays such as those used in audio can become intermittent due to the fact that the current passed by the contacts is so small. Relays carrying higher current are "self cleaning" and tend to develop less problems.
The best way to ascertain the problems in a circuit such as this is by signal tracing on the board. But check the notes above first.
Mark