Happy Trails HTP5-4-5.1 User manual

Remove the screw from the bottom of the tank as
shown in Fig 1. Repeat this process on both sides of the
motorcycle.
Place an M875C bolt with a 5/16” at washer through
the lower hole in the NERF bar, then into the hole in
the bottom of the tank noted in Step 1. Tighten this
bolt until snug to hold the engine guard in place while
completing Step 3.
Installation on both sides of the NERF bar are the iden-
tical.
Place an aluminum frame clamp on the frame tube
near the rear of the motor as shown in Fig 3.
Place a plastic spacer between the NERF rear mount-
ing point and the aluminum frame clamp. Insert two
M625C screws through two 3/16” atwashers. Slide the
screws through the NERF bar mounting point, plastic
spacer and begin tightening them into the aluminum
frame clamp. Do not tighten these bolts completely.
Fig1
Fig 2
Fig 3
Step 1
Step 2
Step 3
HTP5-4-5.1 KTM 950/990 NERF BAR
ank you for purchasing Happy Trails products. Our products are proudly hand made in Boise
Idaho, USA. If you have any questions or concerns about the installation of this product, please con-
tact us directly at 1-800-444-8770 or e-mail [e-mail].
Before you begin, place the bike on a hard level surface where you have room to work. Lay out the
parts included in this kit and compare to the parts list on the nal of these instructions. If any parts
or hardware are missing, contact us immediately at the number or email listed above.

4/13/12
Rev. 1
HH
Recommended Tools:
13MM Wrench
6mm Allen Wrench
5MM Allen Wrench
Hardware List:
Right Side NERF Bar
Le Side NERF Bar
Right Side Support
Le Side Support
Two Aluminum Frame Clamps
Two Plastic Spacers
Remove the bolt from the hole indicated by the arrow
at the bottom of Fig 4. Refer to this mounting point for
Step 5. Allign the support bar as shown. e le side
and right side support bars dier so ensure the top tab
lines up correctly with the NERF bar before inserting
bolts.
Place a 5/16” atwasher on a M825C bolt and insert it
through the upper tab in the NERF bar and through
the support bar. Place an additional 5/16” at washer
and M8N on the back of the bolt. Do not tightent this
bolt completely.
At the lower support bar mount noted in Step 4, place
a 1/2”L x 3/4” OD x .319” spacer between the support
bar and the recess in the frame section near the header
pipe as shown in Fig 5. Insert an M845C bolt and 5/16”
atwasher through the support bar and spacer and
thread it into the frame section.
You may not tighten all bolts completely.
M8 bolts should be torqued to 18 /lbs
M6 bolts should be torqued to 9/lbs .
Fig 4
Fig 5
Step 4
Step 5