Happy Trails KLR 650 ELITE User manual

Using a 5mm Allen wrench and a 10mm open end
wrench, remove the (2) bolts attaching the turn signal
to the OEM tail rack and let the turn signal hang out of
the way. See Fig 1.
Repeat for other turn signal.
Using a 5mm Allen wrench, remove the (2) bolts near
the center of the tail plate. See Fig 2.
Remove the OEM Tail Plate, unattach the turn signal
wiring from the bottom of the tail plate, and set the
turn signals out of the way. See Fig 3.
Fig1
Fig 2
Fig 3
Step 1
Step 2
Step 3
HTP4-8-7 KLR 650 ELITE TAIL PLATE SYSTEM
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 pages of these instructions. If any
parts or hardware are missing, contact us immediately at the number or email listed above.

THIS STEP 4 IS SHOWN AS USED WITH A HAPPY
TRAILS SU RACK.
Attach the side plate MT-1 with the angled end to-
ward the rear and angled up. At the rear bolt location,
place the turn signal relocation bracket MT-2 behind
the riser plate with the large end toward the rear and
angled out. Bolt together with an M8x65 SHCS, 2 at
washers, a 3/4”OD x .319”ID x 1/2” L aluminum spacer,
and an M8N lock nut. Position the turn signal bracket
straight back and tighten the mount bolt to 18 /lbs.
At the front mount use an M8x80 SHCS, lock washer,
at washer and a 3/4” x .319” x 3/4” aluminum spacer.
Tighten to 18 /lbs See Fig 4.
Repeat on the other side.
Attach the turn signal to the mounting bracket MT-2 as
shown in Fig 5 using 2 M6x20 SHCS bolts, 4 at wash-
ers and 2 M6N lock nuts.
NOTE: On the le side, the included wire extension will
need to be installed to gain enough wire slack for mount-
ing the turn signal. e right side is longer and will have
enough wire with a little rerouting.
Tighten these bolts to 9 /lbs.
Repeat on the other side.
Fig 5
Step 4
Step 5
THIS STEP 4a IS SHOWN AS USED WITHOUT A
HAPPY TRAILS SU RACK.
Attach side plate MT-1 with the angled end toward the
rear and angled up. At the rear bolt location, place the
turn signal relocation bracket MT-2 behind the side
plate with the large end toward the rear and angled
out. Bolt together with an M8x30 SHCS, 2 at washers
and an M8N lock nut. Position the turn signal bracket
straight back and tighten the mount bolt to 18 /lbs.
At the front bolt location use an M8x35 SHCS, lock
washer and at washer. Tighten to 18 /lbs. See Fig 4a.
Repeat on the other side.
Fig 4
Fig 4aStep 4a

Place (2) 1/2”OD x .257”ID x 5/8”L aluminum spacers
on the center mounting holes as shown in Fig 6.
Attach the top plate to the side plates using (4) M8x25
BHCS bolts, (8) at washers, and (4) M8N lock nuts.
See Fig 8. Do not tighten these bolts yet.
Fig 8
Step 6
Step 8
Lay the Top Plate in place and thread (2) M6x40 BHCS
bolts with lock washers and at washers through the
two center holes as shown in Fig 7. Do not tighten
these bolts yet.
Fig 6
Fig 7Step 7

4/1/14
JE
Rev. 2
Recommended Tools:
Allen wrenchs;
4mm
5mm
Open end wrenchs;
10mm
13mm
Hardware List:
1 Tail plate
2 Side plates L&R (MT-1)
2 Turn signal brackets (MT-2)
1 Wire Extension
1 Bolt Kit
1 Instruction set
Tighten the (2) M6x40 BHCS bolts from step 7 to
9 /lbs.
Tighten the (4) M8x25 BHCS bolts from step 8 to
18 /lbs.
Congratulations! You are done installing your
Elite Tail Plate System.
Fig 9Step 9
MT-1 MT-2 MT-2 MT-1
18 /lbs 9 /lbs
Rev 2: Added wire extension to kit

KLR ELITE TAIL PLATE HTP4-8-7
x4
M6N
x4
x10
x4
x2
6mm FW
8mm FW
x10
M8N
x6
M865S
M620B
M640B
6mm Lock
Washer
x2
M825B
8mm Lock
Washer
x2
M880S
M830S
M835S
x2 x2
x2 x2
OD3/4, ID .319, L 1/2”Spacer
x2
OD1/2, ID .257, L 5/8 Spacer
x2
OD3/4, ID .319, L 3/4 Spacer
x2