[BareKat]

I double checked the valve cover gasket as well as the gaskets around the spark plug hole after I adjusted the valves.

With respect to the mount... There are two at the front, two at the back and one on each side... d'ya think the one broken mount will cause me grief?

Rexazz, 10-4 on the stop leak...

Doubt it is a head gasket but could be possible

oil leaks downward and backwards (gravity and wind)
Clean the area with brake clean and look after the motor has warmed up

I thought I found the culprit but after looking at the cylinder head on my work bench I don't see any gasket missing (see pics). The oil seams to be leaking right around that area but the valve cover is dry.

remember there is an oil/water drain right below the exhaust pipes so if you have oil around the head gasket it could be a leak around the spark plug valve cover gasket, leaky plug or if you dumped any oil down the cylinders etc it can leak out this lil drain hole.
clean it off really well and keep an eyey on it.
I would honestly rebuild that motor mount before you put it all together.
Aluminum welding rods can be had for $15 buck and will do the trick.
do a searsh on youtube or aluminum welding rods. The tricky part is building the mold, but if you know someone with a mig welder you can make a mold easily then place the bolt in position and weld around it. when it cools the bolt will back out without any problems and you have a new mount already threaded (if you wish)
this stuff is STRONG to.

[rexazz2]

the plug in the picture doesnt appear to have a sealing gasket
and its right behind the frame
I see you put some silicone where I said

chances are the broken mount wont be a problem and its not going to be worth it for you to return the engine
It would always be in the back of my mind
It is easier to fix now than after its all back togather

[BareKat]

I can't even torque that plug down because of the frame...

[Wild-Bill]

Harbor Freight has the aluminum welding rods.

[BareKat]

Now that is the coolest thing I've seen... very cool!

Aluminum welding rods can be had for $15 buck and will do the trick.
do a searsh on youtube or aluminum welding rods.

[hardlydangerous]

just for chits and giggles i cut an old clutch lever in half, wraped a piece of shim stock around the cut and clamped it and welded the lever back together. I put it in the vice and went at it with the hammer. I broke the lever off about 2" above the weld. Its strong stuff. Ive repaired a lot of cases, pegs, stripped threads etc with them and never a problem. Like I said the hardest part is making a mold to hold the melted rod until it cools but new mounts can be made

[BareKat]

Guys, any recourse through paypal/ebay on the broken motor mount and leaks?

This is a quote from the ebay ad, "This motor off a running 1998 Suzuki Katana 750 is in excellent condition, 16K miles, ready to install fits all 98-01 Katana 750."

I wouldn't consider the motor with a broken motor mount to be in "excellent condition" and ready to install? ... although I did ultimately install and start the engine with the broken mount. I guess the concern is that the oil leak from the lower left may be associated with the damaged casing.

[steves]

I have not been following the thread TOO closely. But what are the chances that the damage happened in transit?

[Wild-Bill]

just for chits and giggles i cut an old clutch lever in half, wraped a piece of shim stock around the cut and clamped it and welded the lever back together. I put it in the vice and went at it with the hammer. I broke the lever off about 2" above the weld. Its strong stuff. Ive repaired a lot of cases, pegs, stripped threads etc with them and never a problem. Like I said the hardest part is making a mold to hold the melted rod until it cools but new mounts can be made

Out of curiosity, what sort of torch are you using for that? I had some of those rods given to me and was told that a propane torch is hot enough but I've also been told that you need at least MAPP gas/O2. I also had a welder at a boat shop griping about something I brought him (friend's intake manifold) because we had tried repairing it with the rods. He said it would have been better if we hadn't even tried that.

[BareKat]

I suppose that could have happened. I'm in discussions with the seller now to return the engine to him... what a pain!

I have not been following the thread TOO closely. But what are the chances that the damage happened in transit?

[rexazz2]

Out of curiosity, what sort of torch are you using for that? I had some of those rods given to me and was told that a propane torch is hot enough but I've also been told that you need at least MAPP gas/O2. I also had a welder at a boat shop griping about something I brought him (friend's intake manifold) because we had tried repairing it with the rods. He said it would have been better if we hadn't even tried that.

usually thats a good reason for them to charge you extra

the mini O2 tanks dont last very long and I have never been impressed with the map bottles on my soldering torch

[hardlydangerous]

i use propane or butane torch. normally just propane. just be sure the consentrate the heat on the piece you welding to

[steves]

I suppose that could have happened. I'm in discussions with the seller now to return the engine to him... what a pain!

Finding a welder and getting the motor mount repaired might be easier... just saying....

[BareKat]

Understood but there is a leak in that same area and I'm concerned the bottom half of the casing is cracked. That'll be a someofabitch to find and fix.

I would rather deal with the engine removal and return rather than screwing around trying to have it repaired. If I wanted to screw around with the bottom end I'd just have the bearings in my engine repaired.

Finding a welder and getting the motor mount repaired might be easier... just saying....

[hardlydangerous]

or just drop this crank and rods into your old engine.

I would change the oil pump as well or at least inspect the one you had in your ol engine.. that could be done in an afternoon. just need a couple gaskets