Happy Trails HTP9-5-1.1 User manual

1
Yamaha XT250 SU Rack htp9-5-1.1
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 hardlevel
surface where you have room to work. Lay out
the parts included in this kit and compare tothe
parts in these instructions. If any parts or hard-
ware are missing, contact us immediately atthe
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.
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 using8x25
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.

2
Step 4
Mount the turn signal bracket to the original turn signal mount using
the 8x25mm bolts & 8mm nuts and then mount the turn signals tothis
bracket. We suggest to drill two holes (one on each side) and guide
the wires through the fender. If the bracket touches the fender, you
may add the included washers to space between the provided turn
signal mount and the original turn signalmount.
Turn signal relocation
mounts
Turn signal
relocation
bracket
Original turn
signal mount
Holes

3
4 M8X20mm SHCS
4 M8x25mm SHCS
4 M8X55mm SHCS
4 M6x16mm SHCS
6 8MM NYLOCK NUT
4 6MM NYLOCK NUT
8 M6 FLAT WASHER
16 M8 FLAT WASHER
4 5/8” OD x 1 1/4” long spacers
Hardware
List:
Left and right SU rack
Rear bumper
L&R grab handles
Turn signal
re-located
and installed
Turn signal bracket
Bolt List:
Rev. 3 7/27/16
ZA