Happy Trails KLR 650 ELITE Quick Start Manual

Tail plate system

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HTP4-8-7
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 con-
tact us directly at 1-800-444-8770 or e-mail installation@happy-trail.com.
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 final pages of these instructions. If any
parts or hardware are missing, contact us immediately at the number or email listed above.

Step 1

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.

Step 2

Using a 5mm Allen wrench, remove the (2) bolts near
the center of the tail plate. See Fig 2.

Step 3

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.
KLR 650 ELITE TAIL PLATE SYSTEM
Fig1
Fig 2
Fig 3

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Summary of Contents for Happy Trails KLR 650 ELITE

  • Page 1 HTP4-8-7 KLR 650 ELITE TAIL PLATE SYSTEM 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 con- tact us directly at 1-800-444-8770 or e-mail installation@happy-trail.com.
  • Page 2 Step 4a Fig 4a 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.
  • Page 3 Step 6 Fig 6 Place (2) 1/2”OD x .257”ID x 5/8”L aluminum spacers on the center mounting holes as shown in Fig 6. Step 7 Fig 7 Lay the Top Plate in place and thread (2) M6x40 BHCS bolts with lock washers and flat washers through the two center holes as shown in Fig 7.
  • Page 4 Step 9 Fig 9 Tighten the (2) M6x40 BHCS bolts from step 7 to 9 ft/lbs. 18 ft/lbs 9 ft/lbs Tighten the (4) M8x25 BHCS bolts from step 8 to 18 ft/lbs. Congratulations! You are done installing your Elite Tail Plate System. MT-1 MT-2 MT-2 MT-1 Hardware List:...
  • Page 5 KLR ELITE TAIL PLATE HTP4-8-7 6mm Lock 6mm FW M620B Washer M640B M825B M830S M835S 8mm Lock M865S 8mm FW Washer M880S OD3/4, ID .319, L 1/2” Spacer OD3/4, ID .319, L 3/4 Spacer OD1/2, ID .257, L 5/8 Spacer...

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