Suzuki Marauder 800 Clutch Replacement - Part 3 - Clutch Reassembly

Covers clutch replacement on a 1999 Suzuki Marauder 800 - VZ800. Applicable to all years (1997-2004) of US models of the Marauder. This is part 3, covering reassembly of the clutch, including installation of new driven and drive (friction and steel) plates and new bolts and springs. Basic theory of operation is also discussed in this section.

[@robertb9205]

All good videos on this clutch replacement. They were VERY helpful to me in changing clutch in my stepsons 2000 VZ800. What I found was helpful in putting the short clutch bolts in is since the base plate they bolt on to can move back deeper into the center clutch area is use a long bolt to be able to reach it and draw it forward. Then put in three short bolts and then replace the long bolt with a proper short bolt.That way you don't have to push in to compress the springs to catch the threads of the bolt. Marauder is back on the road and saved about $600!!!

[@ericboehm4529]

Thank you very much! I'm glad you found it helpful. That's a great suggestion on the order of re-installation of the clutch bolts. I'm happy to report now nearly 3000 miles later, the clutch is still working fine!

[@alexmacdiver]

Hello. This comment helped me a lot today. Thank You

[@mauricewalker902]

Nice solid video sir.. Now i have the confidence to do it myself.. Thanks for taking the time to explain it for us "dummies" good Freaking video!

[@ericboehm4529]

Maurice Walker Thank you, Maurice. Good luck with your project. I'm happy to report that mine is going strong almost a year later.

[@richardbutler2807]

Thanks grate video Rich in the UK.

[@uldisermansons]

Good afternoon! I do have a slight problem with this clutch though. I do not understand how and according to what principle these eight short and long screws should be screwed. I put it together, but the clutch does not work. Thank you!

[@Peyton160]

this was very help full what kind of difference can i espect

[@user-py3lr3rx5e]

Y did my clutch seem to go out after my clutch cable broke

[@0521chad]

On that wave washer? The bevil edge; does it go in towards the motor, or away?

[@martinenriquez4782]

Cuántas libras y llevan los tornillos que sujetan al enbrge saludos desde Huatabampo sonora México

[@Cody-j9m]

What is the purpose of using all the same size spring are they tighter then the oem springs ?

[@ericboehm4529]

Yes, the replacement springs are all stiffer than OEM to start with. Using the longer ones in each hole helps give a tighter clutch grip. Marauders are notorious for slipping clutches.

[@Cody-j9m]

@@ericboehm4529 I think that is the issue I’m having is the clutch slipping, at like 3/4 throttle in fourth and fifth gear it revs out, but doesn’t accelerate

[@sumitkkanungo5423]

when I start the my 2012 model m109r, the sound of rattling sound comes from the side of the clutch and as soon as you press the clutch lever, the sound stops what is the problem of the thing please help me

[@erikkontar2641]

I have the exact same issue after I replaced the clutch set on my Marauder 98. I did couple of km, everything was fine, and then such a rattling sound started to come out from the clutch cover, but when I press the clutch lever, even just a bit, it stops. So I decided to disassamble it again to check if I find what caused it, but did not find anything. After assembling it worked again for a while, and then it started again. I heard from more people having this problem, but without any findings.

[@oldman8141]

I was thinking about buying a 2000 Suzuki marauder with 18000 miles on it would you recommend this bike? I’m 6’ 260 lbs? Thanks for the videos

[@ericboehm4529]

Hi, sorry for the late reply. At 6', your legs are definitely longer than mine. You may find the Marauder a little cramped. You'd have to try it out! Also, aftermarket forward controls to extend the pegs are still around.

[@oldman8141]

@Eric Boehm it's cool I bought an 04 vl1500 it's been real nice just need a new seat lol

[@codybosse7178]

Is there anyone who knows what springs he used

[@ericboehm4529]

Cody Bosse They are Vesrah SK-329, all 8 the same size. www.denniskirk.com/vesrah/heavy-duty-clutch-spring-kit-sk-329.p382215.prd/382215.sku

[@johnking6287]

Each spring how many pounds?

[@marcinpilc2915]

😢