How to patch an XS650
oil screen
Blaine Hoopes Oct. 1998
The oil screen in the bottom of the oil pan seems to tear in the same place almost as soon as you replace it with a new one. You can patch a torn screen and it will not tear again. Here is a picture of a torn screen:
Not having any sheet metal lying around and having an weakness for tuna salad sandwiches I used the lid of a tuna can to make a patch. Here is a picture of a tuna lid after cutting to shape, hammering it flat and sanding the coating off the edges:
The edges of the patch and the edges of the oil screen need to be sanded, filed or scraped down to a clean, bare metal surface so the solder will flow and stick properly. I used a regulated heat soldering iron that is intended for electronic use but it seemed to get plenty hot enough to do the job. Since the surfaces had been sanded clean, I did not use acid core solder or any flux. I used regular electronic, rosin core solder (however I chose solder with a higher tin/lead ratio since it is a bit harder). Here is a picture of the patched screen:
I used Permatex gasket glue under both ends where there is no solder. You could try to solder the edges to the screen itself but it's difficult getting the screen clean enough for solder to stick to. Since this screen was torn almost up to the black magnet the patch needed to go all the way to the magnet so gasket cement seemed a better option. NOTE: others have used JB Weld with good luck, I have not put enough miles on this patch yet to confirm that the permatex has held up. I'll update this after I do.
UPDATE 8-6-99: I now have 3-4,000 miles on this patch and the solder has held with no cracks, the permatex is still sealing and there are no new tears in the screen.