1999 Suzuki Marauder timing

Hey James...
Are the floats all plastic?? .Just wondering...

here is a great reference.. keep for long term...
Suzuki VZ800 Marauder 1997 2004 Repair Manuals

I would stick to 25 thou.

Answer

If this is a single overhead cam, possibly A15SMS (engine type):

If you have everything stripped down and can see the crank shaft gear, you will notice an arrow stamped into one of the gear teeth.
this arrow must point towards the bottom, you will notice a mark (notch) cut into the housing, line the arrow on the gear with this notch.

remove the four 10mm bolts that secure the top cover of the timing belt, gently open the cover (not removing it) to see the Cam Gear. You will not be able to remove the cover because of the design.

The Cam Gear should have a line stamped into one of its teeth, this should be pointing up and towards the top. On the inner cover you will notice a notch in the casing, line both up together if it is not already.

You can check the following if unsure:
Remove # 1 spark plug (nearest the Cam Belt) and place a long screwdriver in the hole carefully to feel the piston is at the top, #2 and 3 will be down and the last one #4 at the distributor end will also be up.

Remove the rocker cover and you should see the Cam loabes on #1 piston free, (no pressure on the cam shaft) meaning the valves are closed.


tim

from autozone.com

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Disconnect the Manifold Air Temperature (MAT) sensor connector.
4. Disconnect the air cleaner outlet hose from the throttle body.
5. Disconnect the breather tube from the camshaft cover.
6. Remove the air cleaner housing bolts.
7. Remove the air cleaner housing.
8. Remove the right front wheel.
9. Remove the right front wheel well splash shield.
10. Remove the serpentine drive belt.
11. Remove the crankshaft pulley bolts and the crankshaft pulley.
12. Remove the right engine mount bracket.
13. Remove the front timing belt cover bolts.
14. Remove the front timing belt cover.
15. Using the crankshaft gear bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.
    

Fig. Aligning the timing mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.

1. Fig. Aligning the camshaft gears with the notches on the camshaft cover.
3. Align the camshaft gears with the notch on the camshaft cover.
4. Remove the timing belt.
5. Loosen the automatic tensioner bolt. Turn the hex-key tab to relieve belt tension.
6. 
   

To install:

1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover.
2. Align the timing marks on the camshaft gears, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
3. Install the timing belt.
4. Turn the hex-key tab in a clockwise direction to tension the belt. Turn until the pointer aligns with the notch.
5. Install the automatic tensioner bolt and tighten to 18 ft. lbs. (25 Nm).
6. Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt.
7. Recheck the automatic tensioner pointer.
8. Install the front timing belt cover.
9. Install the front timing belt cover bolts and tighten to 53 inch lbs. (6 Nm).
10. Install the right engine mount bracket.
11. Install the crankshaft pulley and tighten the crankshaft pulley bolts to 15 ft. lbs. (20 Nm).
12. Install the serpentine drive belt.
13. Install the right front wheel well splash shield.
14. Install the right front wheel.
15. Install the air cleaner housing.
16. Install the air cleaner housing bolts and tighten to 89 inch lbs. (10 Nm).
17. Connect the air cleaner outlet hose to the throttle body.
18. Connect the breather tube to the camshaft cover.
19. Connect the MAT sensor connector.
20. Connect the negative battery cable.

You did not specify manual or automatic transmission. You actually have 4 marks to set up your cam, intermediate shaft (distributor) and your crankshaft. To rotate the motor over by use of a socket and ratchet, either loosen or remove your spark plugs. Remove the green colored plug on top of the transmission, it is located below your coolant tank. You will see either your flexplate (auto) or your flywheel (man) with notches on the outside diameter. Next, go to the lower belt pulley on the passenger side. You can use a 12 point socket on the center bolt to rotate the engine over. On the same pulley you are about to turn, there is a notch on the inside pulley edge. Look at the black lower timing belt cover between the pulley and engine block. You will see a small arrow at around 1:00 (as you look at the pulley). When the crankshaft is on #1 cylinder TDC, the small notch on the pulley will line up with this arrow. Now go back to the hole on top of the transmission. You'll see at the bottom of the threads an arrow. There is a diamond or oval shaped mark on the flywheel that lines up with this arrow. This is your crankshaft timing mark and will be used for enging timing. Use a white paint stick or something to mark it if is not clear.

There are two other marks for cam and distributor timing. With the crank at #1 TDC, remove the distributor cap. Note the rotor position. It should be pointed at the #1 spark plug. Pull straight up on the rotor to gain access to the thin black piece of plastic that covers the pickup. Remove the thin plastic cover and look at the aluminum edge and you will see a notch there too. This should be below your #1 plug wire.

The last one is on the camshaft gear. With the valve cover in place and cork gasket under it, remove the two 10mm nuts that hold the upper timing belt cover in place. One the bottom of the same cover, you'll find a shouldered nut. Remove it with an allen wrench. You can remove the upper cover now. From the front of the engine, look at the gear and find the single dot on the inside edge. Some gears have a dot on the outside but that is not what your looking for. The dot should be at the same height at the valve cover bottom edge (where the 8 bolts hold it down). If these three notches and dot are all in place, the timing belt is on correctly.

Hope it helps!

FORK OIL
• Place the front fork vertically without spring.
• Compress it fully.
• Pour specified front fork oil up to the top level of the outer
tube.
 Capacity (each leg): 490 ml (16.6/17.3 US/lmp oz)
 99000-99044-L01: SUZUKI FORK OIL L01
or an equivalent fork oil
• Move the inner rod slowly with the special tool ten times and
more until no more bubbles come out from the oil.
 09940-52841: Inner rod holder
NOTE:
Refill front fork oil up to the top of the outer tube so that bubbles
are visible while bleeding air.
• Refill specified front fork oil up to the top level of the outer
tube again. Move the outer tube up and down several strokes
until no more bubbles come out from the oil.
• Keep the front fork vertically and wait 5 – 6 minutes.
NOTE:
* Always keep oil level over the cartridge top end, or air may
enter the cartridge during this procedure.
* Take extreme care so as to pump out air completely.
• Hold the front fork vertically and adjust fork oil level with the
special tool.
NOTE:
When adjusting the fork oil level, compress the outer tube fully
without the fork spring.
 Fork oil level: 153 mm (6.02 in)
 09943-74111: Front fork oil level gauge

There is a small cover on the bottom center of the transmission. It's held in by 2, 8mm bolts.

To change the timing belt: first place the right side of the vehicle on a jack stand and remove the right front tire. Remove the plastic cover inside the wheel well to expose the harmonic balancer. Remove the serpentine belt (standard 3/8" rachet will set in the belt tensioner to relieve tension). Remove the harmonic balancer (19mm). Place a jack under the engine on the right side of the vehicle, then remove the engine mount from the top of the fender well, (17mm deep well socket and 17mm wrench required) it is not necessary to remove the mount from the side of the engine. Remove the timing cover, (10mm) it has 2 nuts. Loosen the timing belt tensioner, (10mm) then pry it away to relieve the tension. Slide the timing belt off of the cam gear.

To position the new belt, the cam gear has a arrow on it, and the cylinder head has a small dot. Align the arrow with dot, and make sure it is aligned (the arrow must point up). The crank gear has a notch and the engine has a groove to align the notch. Again, make sure the notch and groove are aligned (they again will be up). Place the new timing belt in position around the crank gear, the water pump and belt tensioner and leave the slack at the top. Again relieve any tension from the belt tensioner, and slide the belt on to the cam gear. Place a slight bit of tension on the belt and tighten the belt tensioner. Use the 19mm bolt from the harmonic balancer and turn the engine 2 complete turns and verify that the cam gear and crank gear are in their proper positions and aligned with the dots and notches. After 2 complete turns of the engine, and verifying everything is still aligned, re-assemble in reverse. No further adjustment is necessary.

Note:There is no timing adjustment for this vehicle, and if you are not properly aligned on the cam gear and crank gear it will not run properly.

To change the timing belt first place the right side of the vehicle on a jack stand and remove the right front tire. Remove the plastic cover inside the wheel well to expose the harmonic balancer. Remove the serpentine belt (standard 3/8" rachet will set in the belt tensioner to relieve tension). Remove the harmonic balancer (19mm). Place a jack under the engine on the right side of the vehicle, then remove the engine mount from the top of the fender well, (17mm deep well socket and 17mm wrench required) it is not necessary to remove the mount from the side of the engine. Remove the timing cover, (10mm) it has 2 nuts. Loosen the timing belt tensioner, (10mm) then pry it away to relieve the tension. Slide the timing belt off of the cam gear.

To position the new belt, the cam gear has a arrow on it, and the cylinder head has a small dot. Align the arrow with dot, and make sure it is aligned (the arrow must point up). The crank gear has a notch and the engine has a groove to align the notch. Again, make sure the notch and groove are aligned (they again will be up). Place the new timing belt in position around the crank gear, the water pump and belt tensioner and leave the slack at the top. Again relieve any tension from the belt tensioner, and slide the belt on to the cam gear. Place a slight bit of tension on the belt and tighten the belt tensioner. Use the 19mm bolt from the harmonic balancer and turn the engine 2 complete turns and verify that the cam gear and crank gear are in their proper positions and aligned with the dots and notches. After 2 complete turns of the engine, and verifying everything is still aligned, re-assemble in reverse. No further adjustment is necessary.

Note:There is no timing adjustment for this vehicle, and if you are not properly aligned on the cam gear and crank gear it will not run properly.

these bend valves if belt breaks while running
Align the timing marks on the camshaft gears to the notches on the camshaft cover, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
Align the mark on the crankshaft gear with the
notch at the bottom of the rear timing belt cover.

There is no timing adjustment "at all" for a 1999 escort. If your timing is out, your timing belt has slipped and needs to be replaced.

To change the timing belt first disconnect your negative battery cable, then place the right side of the vehicle on a jack stand and remove the right front tire. Remove the plastic cover inside the wheel well to expose the harmonic balancer. Remove the serpentine belt (standard 3/8" rachet will set in the belt tensioner to relieve tension). Remove the harmonic balancer (19mm). Place a jack under the engine on the right side of the vehicle, then remove the engine mount from the top of the fender well, (17mm deep well socket and 17mm wrench required) it is not necessary to remove the mount from the side of the engine. Remove the timing cover, (10mm) it has 6 bolts and nuts. Loosen the timing belt tensioner, (10mm) then use a 3/8" rachet in the belt tensioner to relieve the tension. While relieving the tension slide the timing belt off of the cam gear.

To position the new belt, the cam gear has a arrow on it, and the cylinder head has a small dot. Align the arrow with dot, and make sure it is aligned (the arrow must point up). The crank gear has a notch and the engine has a groove to align the notch. Again, make sure the notch and groove are aligned (they again will be up). Place the new timing belt in position around the crank gear, the water pump and belt tensioner and leave the slack at the top. Again use a 3/8" ratchet to relieve any tension from the belt tensioner, and slide the belt on to the cam gear. Place a slight bit of tension on the belt and tighten the belt tensioner. Use the 19mm bolt from the harmonic balancer and turn the engine 2 complete turns and verify that the cam gear and crank gear are in their proper position and aligned with the dots and notches. After 2 complete turns of the engine, and verifying everything is still aligned, re-assemble in reverse. No further adjustment is necessary.

Note:There is no timing adjustment for this vehicle, and if you are not properly aligned on the cam gear and crank gear it will not run properly.