Cut Windshield Down to Size - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 7 Old 06-01-2007, 07:40 PM Thread Starter
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Cut Windshield Down to Size

Got fed up with the buffeting wind moving my helmet around and no fresh air coming in the full face helmet. My buddy and I masked off the windshield and removed about 2 1/2 inches. We radiused the corners using a roll of tape to mark the radius at each corner. Then using 400 grit sandpaper, cleaned up the cut edge then scuffed the back side of the windshield and painted it gloss black to match the fairing. This is so much better now. The wind hits me at chest level and I am now getting the fresh air flow I was missing. Also I took off the factory skid plate and notched it out to allow access to the tensioner adjusting bolt. Speaking of, I adjusted the bolt and could feel and hear an immediate difference in sound and less vibration. If it was that bad at 800 miles, I am sure I need to get the upgraded doohickey put in soon. I also got my buddy talked into buying a KLR. Problem is he has got to sell his foreman 450 4x4. Anyone know of someone looking for an extra nice 2001 foreman pm me. I can get some pictures of it in a day or two.
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2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #2 of 7 Old 06-01-2007, 08:08 PM
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Nice clean job on the windscreen.Looks good in black

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thank a soldier.
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post #3 of 7 Old 06-01-2007, 08:26 PM Thread Starter
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Quote:
Originally Posted by klrmike View Post
Nice clean job on the windscreen.Looks good in black
Thanks, I need to get a better picture, it was just beginning to storm and I had to hurry with the pics and get the bike covered.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #4 of 7 Old 06-01-2007, 10:55 PM
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Did the same with my stock screen. Wound up using the +4 screen from Kawasaki. Clean air to the helmet was not an issue either way but when in the dirty air that 65mph traffic creates I found the +4 works best for me.

'06 KLR650
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post #5 of 7 Old 06-01-2007, 11:32 PM Thread Starter
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I figured this was the best thing I could do till I decided to try a +4. I know the +4 probably has to be a great help against rain and colder weather. The issue with air comes with the hot temps we been having lately and sweating so much in the helmet. Now with air movement I am able to stay cooler. Dirty air not too much of an issue around here with the traffic.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #6 of 7 Old 08-11-2007, 01:20 PM
 
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what did you use to cut it???
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post #7 of 7 Old 08-11-2007, 06:19 PM Thread Starter
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jigsaw with fine tooth blade. Radiused the corners with grinder. used a coffee can to outline the corners with before cutting.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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