kle 500 home made screen
Just thought I'd add my 2 cents worth, even though I've got the older model '98 KLE 500:
After buying a taller Ermax screen (maybe 15cm taller) that actually made the buffeting and wind noise worse, I decided to make my own screen. I've tried the bike with the screen removed, which helps but the wind noise is still pretty bad (possibly arai helmet?), and my body gets tired on my hour commute to work at 80+ mph. I'm 6'3" and have redone my seat so that I'm sitting maybe 10-15cm higher on the bike.
I bought a piece of 3mm thick Lexan (Polycarbonate), size 60 x 40cm. I then used the standard screen to mark off bend lines etc, then used a heat gun to heat the sheet and bend it (man, it's really tough stuff - no need to worry about breaking it). I used an electric jigsaw with steel cutting blade to trim the edges to fit the bike. I then drilled mounting holes, and had to recess the screen sides to clear the mirrors/handguards with the steering at full lock.
So, the new screen is great. It is probably level with my nose, and sends the air only over the top of my helmet, reducing noise greatly.
This type of screen would be much easier to make for the newer model KLE with its simplified screen mountings.
I'll take some pictures if anyone is interested.