MADSTAD ENGINEERING Kawasaki KLR650 Adjustable Windshield System Installation Guide

: June 17, 2024
: MADSTAD Engineering

Table of Contents

What is in the box:
Windshield Installation
Disclaimer
Customer Support
Documents / Resources

MADSTAD ENGINEERING Kawasaki KLR650 Adjustable Windshield System

Please read this entire manual before proceeding with installation.

What is in the box:

Set of adjustable windshield brackets
Black mounting plate (with 2 rubber well nuts installed)
M6 x 16 button head screws
M6 flat washers
M6 lock nuts
M5 Phillips truss screws
M5 Flat plastic washers
M5 Rubber washers

Rear Brace Kit

(2) aluminum rear braces
(2) spacers
(2) long bolts M6 x 75mm
(2) M6 metal flat washers
(2) M5 metal flat washers
(2) M5 lock nuts

MadStad adjustable brackets are designed to bolt to a curved surface like the mounting plate included in this kit. The new windshield attaches to the top of the brackets with the M5 Phillips truss screws, flat plastic washers, and soft rubber washers. Loosening the two adjustment knobs allows you to change the windshield height and tilt without getting off of the bike, and without any tools

Step 1: Remove your factory windshield; it is not adaptable for use with these brackets. Save the screws and plastic washers, you will re-use those to mount the MadStad mounting plate

Step 2: Attach the MadStad brackets to the mounting plate as shown on page 3. Use the four M6 x 16 screws with washers and lock nuts as shown in the diagram below.

What is in the box:

The knobs on the brackets go to the insides (facing each other) with the knob sides up. When both brackets are installed it should look like the diagram below:

The adapter plate then slides into the fairing in place of the stock shield. You may have to tilt it a bit to get the rubber well nuts (which are in the bottom two holes) over the instrument cluster but it will slide in. Then install the bottom two factory screws into the bottom two well nuts and tighten. You will install the top two screws in the next step.

Step 3: Rear Brace Kit

The top two factory windshield screws are used with the rear braces to support the upper side of the system. Refer to the image below for installation. Install the long bolts and spacers first, but leave slightly loose so you can rotate and maneuver the braces into place behind the mounting plate. Then use the factory screws, washers and nuts to secure the brace to the back of the mounting plate and finish tightening the long bolts.

Step 4:

Windshield Installation

Pre-install the Truss screws & washers into the windshield holes as shown in the image below.
Once all four of the screws are in place, gently guide the screws into the Well Nuts in the brackets until all four are set.
Hand tighten the Truss screws until they swell up behind the bracket and are firmly holding the windshield.

Windshield Layout:

Windshield Layout

Well Nut TiPs:

HAND TIGHTEN

Well Nut TiPs:

Adjusting the MadStad Brackets

The knob screws release the brackets allowing the windshield to slide and tilt. These screws must always be tightened securely before riding. DO NOT attempt to adjust the brackets while riding! You must come to a complete stop before making adjustments. Also make sure that you do not set the windshield in such a way that causes your handlebars or hand guards (if installed) to hit the windshield when turning, or before reaching full lock.

To make adjustments, loosen the knobs 1-2 turns and set the windshield so the top edge is at about your chin level as you look straight ahead while seated on the bike. Set the angle at approximately 60 degrees. (Use the angle guide on the back page of this manual as a guide.) Tighten the knobs and go for a ride to see if you now have smooth airflow over and around your helmet. Do this on a calm day if at all possible; windy days make it hard to judge the airflow. Don’t ever try to adjust the mount while in motion! It may take a few tries and adjustments but once you find your most comfortable setting, you are done!

Notes on Windshield Angle

Most windshields work best when set at a 55-60 degree angle. We have provided an angle guide on the back page of this manual so that you can check and see if your shield is set somewhere in this range.

To check your shield angle, your bike should be in an upright position either on a center stand or held up by a helper. Set the spine (folded edge) of the manual against the front of the shield. If the large arrow marked 60° is pointing straight up, then your shield is at a 60 degree angle. (See diagram on Page 5.) A little farther back and your angle would somewhere between 55 and 60 degrees. Anywhere in this range is fine for your initial test ride. On some bikes a more vertical angle works better, so don’t be afraid to experiment later if tilting the shield back doesn’t seem to be ideal.

Disclaimer

Neither MadStad Engineering nor its owners shall be liable for any damages, consequential or inconsequential, resulting from the use of our products. Installation of any of our products constitutes acceptance of these terms.
It is the responsibility of the user to make sure all fasteners are tightened securely, the windshield is mounted properly and the adjustment knobs are tightened snugly before putting the motorcycle in motion. MadStad systems ARE NOT intended to be adjusted while the vehicle is in motion; you must pull over out of the way of traffic and come to a complete stop before making any changes. The user must never place the windshield in such a position as to interfere with the safe and complete movement of the handlebars and controls.

Returns and Warranty

MadStad adjustable brackets carry a lifetime warranty against manufacturing defects. This does not include cosmetic issues nor anyparts that inherently wear out or degrade over time such as rubber and plastic parts. Windshields, deflectors, and other similar plastic parts are warrantied for 1 year against manufacturing defects, not against cosmetic issues or issues related to normal wear and tear. Please visit our website for further details.

Customer Support

MadStad Engineering, Inc.

1451 East Jefferson St., Brooksville, FL 34601 USA Phone: 352-848-3646 Web Site: http://www.madstad.com

Email:support@madstad.com Thank you for your support, and ride safely!

Thank you for your support, and ride safely!

MadStad Engineering, Inc. Logo

Documents / Resources

| MADSTAD ENGINEERING Kawasaki KLR650 Adjustable Windshield System [pdf] Installation Guide
Kawasaki KLR650 Adjustable Windshield System, Kawasaki KLR650, Adjustable Windshield System, Windshield System
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