Happy Trails HTP9-5-1 User manual

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Thank 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 contact us di-
rectly 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 in these instructions. If any parts or hard-
ware are missing, contact us immediately at the
number listed above.
IMPORTANT!!!!
When installing Happy Trails racks, leave all bolt
connections loose until the entire product is in-
stalled. Then go back and tighten all connec-
tions. We recommend the use of thread locking
compound.
Disassembly
Remove the turn signals from their locations.
Remove the upper passenger peg mount bolt.
YAMAHA XT250 SU RACK HTP9-5-1
Step 1
Installation is the same for both sides. Using the
8x20 bolts, mount the grab handle mounts
loosely as shown in picture. Attach the side
racks to the grab handles using 8x55 bolts, 5/8”
OD x 1 1/4” long spacers & 8mm nuts. Attach the
side rack to the passenger peg mount using 8x25
bolts.
Step 2
Once both sides are mounted, but loose, mount
the rear bumper using 4 M6x16 bolts, 3/16 flat
washers and 6M Nylock nuts. Once all mounting
points are mounted, go back and tighten all
points.

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Bolt List:
4 M8X20mm SHCS
4 M8x25mm SHCS
4 M8X55mm SHCS
4 M6x16mm SHCS
6 8MM NYLOCK NUT
4 6MM NYLOCK NUT
8 3/16 FLAT WASHER
10 5/16 FLAT WASHER
4 5/8” OD x 1 1/4” long spacers
2 White 1/4” thick turn signal
Parts List:
Left and right SU rack
Rear bumper
L&R grab handles
Wire extension
Turn signal bracket
Bolt Kit
Step 4
Mount the turn signal bracket to the upper license
plate mount using the 8x25mm bolts & 8mm nuts
(use white 1/4” spacer on turn signal stem if
needed) and then mount the turn signals to this
bracket. Turn signal wires may need to be
lengthened to reach the connectors.