MADSTAD ENGINEERING KTM 390 Duke Adjustable Windshield System Installation Guide
- June 17, 2024
- MADSTAD Engineering
Table of Contents
Adjustable Windshield System
KTM 390 & 690 Duke
Please read this entire manual before proceeding with installation.
What is in the box:
- (1) Pair of Adjustable Brackets
- (4) Aluminum spacers 0.5”
- (4) M8 x 50 screws
- (8) M8 flat washers
- (1) Crossbar (208mm long)
- (2) M6 x 16 screws
- (2) M6 split lock washers
- (2) M6 flat washers
- (4) M5 x 20 Phillips truss screws
- (4) M5 flat plastic washers
- (4) soft rubber washers
This MadStad system attaches above your handlebar clamps using aluminum spacers and longer bolts. Your handlebars do not need to come loose as you can install these brackets one side at a time.
Bracket Installation:
STEP 1 – Remove two of your handlebar clamp bolts ON ONE SIDE ONLY. (If you
remove all four handlebar clamp bolts your bars will come loose, and we don’t
want to do that.)
Remove the bolts but leave the top clamp in place. The MadStad brackets will
bolt on top. STEP 2 – Set two of the aluminum spacers provided in your kit
into the two holes in the now-open top clamp, as seen in the photo above. Put
one M8 flat washer on top of each spacer. To keep it from slipping off, put a
dab of Vaseline or similar thick grease on top of the spacer so that the flat
washer will stick to it and not slide off. Or, pre-assemble the new long bolts
with washers right onto the MadStad bracket as shown at right.
Just hold the bolts and washers in place so they don’t fall out when you go to
set them into the spacers and lower bar clamp.
STEP 3 – Insert the bracket with the new M8 bolts and washers provided right
through the aluminum spacers and into the mounting holes of the bottom bar
bracket. Run the bolts in with your fingers to get them started then bolt them
down so the final result looks like the photo below.
NOTE: Tighten the front bolt completely first, then tighten the back bolt
to factory specifications.
STEP
4 – Repeat steps 1, 2 and 3 for the other set of brackets on the other bar
clamp. The final result will look like the photo above. STEP 5: Crossbar – The
solid aluminum crossbar mounts between the two adjustable brackets as shown at
left. One side of the crossbar has a protruding pin which must sit in the slot
on either bracket, to prevent the crossbar from rotating. Slide the crossbar
between the brackets, align the center hole with the keyhole slot in the
bracket as shown below, then fasten as shown below.The finished assembly
should look like the photo at bottom.
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.
Adjusting the MadStad Brackets
The knob screws release the brackets allowing the windshield to slide and
tilt.
These knob 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.
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. It may
take a couple of extra turns to free up the angle adjustment. Set the angle at
approximately 60 degrees (roughly the same angle as your forks). You can also
use the angle diagram 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 brackets while in motion!
Experiment with different positions at different speeds until you find a
combination of height and angle that give you the smoothest ride. Just a
3degree change in angle or slight change in height can make a difference.
PIVOT SCREWS
The MadStad mount has a pivot screw on each set of brackets, located near the
center of the bottom bracket. A nylon lock nut keeps the screw snugly in
place, yet allows the brackets to slide back and forth. It is adjusted at the
factory to have a minimum of play yet still allow the brackets to move.
If for some reason you wish to adjust the tightness of this pivot screw or
move it to an alternate pivot position, use a 4mm Allen wrench along with a
10mm socket or crescent wrench to make the adjustment. If you tighten the lock
nut completely you will not be able to slide the brackets.
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 any parts 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.
MadStad Engineering, Inc.
1451 E. Jefferson Street
Brooksville, FL 34601 U.S.A.
Phone: 352-848-3646
Web Site: http://www.madstad.com
Email: support@madstad.com
Thank you for your support, and ride safely!
References
- Adjustable motorcycle windshield systems | motorcycle windscreen | Madstad
- Adjustable motorcycle windshield systems | motorcycle windscreen | Madstad