Malone MegaSport MPG550LB User manual

MPG550LB
MALONE
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MALONE
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*ATTENTION CUSTOMERS*
Thank you for your recent purchase of a Malone trailer.
Please inspect all parts and hardware bags prior to assembly.
**Set the large red envelope (in the axle box) containing
important documents in a safe spot.
If you encounter any missing components please contact us at:
Email:[email protected]
OR
Phone:(207) 774 - 9100 X215
Business Hours: Monday-Friday
9am- 5pm
Thank you from all of us at Malone

Important Note
Product Warranty & Registration Form
All information is condential and used exclusively by MALONE only.
MALONE
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Dear Customer,
Thank you for your purchase of a Malone Product.
In order to be eligible for the Malone Warranty program, we ask that you contact us by email or
online at one of the following: With-in 30 days of purchase. You can also mail this letter back to the address at
the bottom.
• Online: www.maloneautoracks.com
• Email: T[email protected]om
We will require the information below.
Here is the information collected:
First Name:
Last Name:
Address:
Address2:
City:
State:
Zip:
Country:
Email:
Phone:
Product Description/Name:
Product MPG#
Date Purchased:
Store Where Purchased:
Purchase Price:
Thank you for choosing Malone!
81 County Rd. Ste 1, Westbrook, ME 04092
P: 207.774.9100 F: 207.615.0551
E: [e-mail] W: www.maloneautoracks.com

800-295-0042 ext 206
[email protected] 1
MPG460XT
Take a few moments and read through these instructions to familiarize yourself
with the step by step assembly process before you begin turning wrenches.
Unpack and sort the components into groups as shown in the following pages.
Then assemble each group in order. Lets get started !!
Required Tools:
• (2) 3/4” wrenches • (2) 9/16” wrenches (a deep socket is recommended)
• Large flat blade screw driver • (1) 7/16” wrench
• Razor knife • Pliers
• Wire stripping tool • Electrical connector crimping tool
• Lug wrench • Small hammer
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for more fine products and accessories.
Malone MicroSport Trailer
Model MPG460XT Assembly Instructions
TM
REV 2
MPG550LB
Malone MegaSportTM Trailer
Model MPG550LB Assembly Instructions
Take a few moments and read through these instructions to familiarize yourself with the
step by step assembly process before you begin turning wrenches.
Unpack and sort the components into groups as shown in the following pages.
Then assemble each group in order. Lets get started !!
Required Tools:
• (2) 3/4” wrenches • (2) 9/16” wrenches (a deep socket is recommended)
• Large at blade screw driver • 7/16” wrench • 3/8” wrench and socket
• Large Phillips head screw driver • Rubber hammer
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MALONE
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+
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Group 1:
Frame
Components
Group 2:
Axle / Spring
Components Bag 11412-1
Bag 11412
Tongue Frame
Main Frame
Visit www.maloneautoracks.com/Replacement-Parts
for all of your spare part needs

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3
Group 4:
Fender Components Bag 11464
Group 3: Lighting Components
Bag 11468
Group 5: Coupler Components
Bag 11494
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for all of your spare part needs

Group 7:
Jack Stand
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Bag 11412-2
Group 6:
Load Bar
Components
x4
x4
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for all of your spare part needs

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MAIN FRAME ASSEMBLY (Group 1)
1. We start the assembly of the Main frame rst, right side up. Aline all the cross members as shown.
NOTE: Direction of 3rd cross member faces forward. Install the bolts downward from the top and secure
with nylon lock nut. Hand Tighten Only.
Measuring from the rear corners diagonally to the front corners will insure your frame is square. Adjust
as needed and fully secure the 4 corners.
We now ip the main frame on its back to make it easier to install the tongue frame, springs and axle.
Once the springs and axle assembly is installed we will ip the trailer over to complete the assembly.
2. With the frame components
upside down as shown install the
remaining hardware for the cross
members, fully tighten the four
corners rst, again measuring to
insure the frame is square.
NOTE: Skip the bolts for the 4th
cross member from the front
until we add the frame rail for
the tongue.
The spring bracket mounting holes
should be facing up. All the decals
should be upside down.
Securing four corners
spring bracket mounting
holes
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3. Identify the hitch end of the tongue by the 3
holes on the left (drivers) side.
TONGUE ASSEMBLY (GROUP 1)
4. Pass the wiring harness (with a plug at each end), into
the open end of the tongue, leaving enough excess at the
front to reach the vehicle. NOTE: MAKE SURE YOUR
PLUG MATCHES THE VEHICLE CONNECTION. IF NOT
REVERSE YOUR WIRING HARNESS NOW.
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8. Begin attaching the tongue components with the side frame
rails rst, then the tongue down the middle.
Tighten the side rails beginning at the 4th cross member back,
going through both the main frame rail and cross member,
joining them together. Working your way forwards, the side
rails will pinch together at the tongue. You’ll use washers on
front 2 cross members utilizing the larger oval holes.
5. Add the tongue safety bolt at the non-coupler end as pictured.
NOTE: Wires removed for clarity
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8. Begin attaching the tongue components with the side frame
rails rst, then the tongue down the middle.
Tighten the side rails beginning at the 4th cross member back,
going through both the main frame rail and cross member,
joining them together. Working your way forwards, the side
rails will pinch together at the tongue. You’ll use washers on
front 2 cross members utilizing the larger oval holes.
6. Begin attaching the tongue components with the side frame
rails rst, then the tongue down the middle.
Tighten the side rails beginning at the 4th cross member
back, going through both the main frame rail and the cross
member, joining them together. Working your way forwards,
the side rails will pinch together at the tongue. You’ll use
washers on the front 2 cross members utilizing the larger oval
holes.
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9. Secure the tongue to the main frame and frame rails with
the at plates and longer bolts. Placing one plate on each
side of the tongue as pictured.
10. Attach the spring
hanger brackets to the
frame. Right at the end
of tongues side rail.
The U shaped shackle
bolt brackets mount
to the front and the C
shaped “slipper” brack-
ets mount to the rear
as shown. Use 3/8” x
1” bolts and nuts. Assemble with the nuts on the inside of the frame
rails. Fully tighten all 8 bolts now.
7.
8.
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SPRING AND AXLE ASSEMBLY
(Group 2)
2. Spin the axle to nd the side with the spring
centering holes. These holes mate with the spring
center stud (shown to the left)
1. Set the envelope containing the manufacturer’s
certicate of origin (MCO) and VIN labels aside in a
safe place.
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*Set the large red envelope
(in the axle box) containing
important documents in a safe spot.

4. Run each nut down UNTIL IT
TOUCHES THE PLATE ONLY!
DON’T TIGHTEN !!
You will need to wiggle the
springs to t them into the
spring brackets in the next step.
5. Lift the axle/spring assembly to the trailer frame and slide the slipper spring
ends into the slipper spring brackets as shown.
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6. Wiggle the spring eyes into the front hanger brack-
ets and bolt using 1/2” x 3” bolts and self locking
nuts. Tighten the shackle bolts ONLY until they grip
the sides of the brackets. This is a hinge, the spring
needs to move freely.
8. Mount the wheels onto the hubs and
hand tighten the lug nuts.
7. Now that the axle assembly is at-
tached to the frame, tighten the axle
plate U-bolts evenly until there is a
slight bend in the tie plates.
9. With 2 people Standing on the
side the trailer, lift the frame rail
member at the corners and ip the
trailer over onto the tires. Carefully
lower onto wheels.
ALWAYS BEND FROM YOUR
KNEES WHEN LIFTING. THIS
TRAILER IS HEAVY TO FLIP
SAFELY ALONE, GET SOME
FRIENDS TO ASSIST YOU.
10. Tighten the lug nuts
rmly to 75 to 85 foot
pounds of torque.
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11. With the trailer now turned right-side up, go back and fully tighten
all bolts and nuts along the frame rails and cross members from Step
1.
FIRST Install the grommets into the small holes along all the
cross members to protect the wiring as we bring it through the
frame.
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LIGHT ASSEMBLY (Group 3)
L.E.D. REFERENCE:
Trailer Wiring Color Code
•Brown = running lights
•Yellow = left turn / left brake
•Green = right turn / right brake
•White = ground
1. First attach the taillight brackets to the frame
as shown using 3/8” x 1” carriage head bolts and
nuts. No washers are needed.
2. Mount the taillights to the light brackets using
the nuts provided with the light kit. *Making sure to
Attach/secure the license plate holder to the
backside of the drivers side lamp bracket as
shown.
*
1 2

3. Use the holes just behind the second cross member to mount the amber side lights. First, push the
wire leads through the outside holes and the lamp stud through the center hole.
4. Secure with the lamp stud nut.
5. Plug in the remaining wiring harness into the connection
behind the tongue. Looking at the end connections, route
the GREEN/BROWN/WHITE wire along the passengers
side. Route the YELLOW/BROWN/WHITE along the
drivers side as shown.
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6. Next, we’ll route the wires through the cross members, One lead at a time, all the way through the
trailer to the tail lights.

7. With the wires routed all the way to the tail lights, rmly
grasp the wiring connections and plug-in matching colored
leads/wires. Repeat with all remaining lights.
8. Use the clips provided to secure the wire to the inside of
the frame channel as shown.
NOTE: THESE UNUSED PLUGS ARE FOR AUXILIARY ACCESSORIES LIKE
THE MALONE MPG543 CHARGING UNIT AND/OR MPG539 FLOOD LIGHT
(NOT INCLUDED)
MPG539MPG543
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FENDER ASSEMBLY (Group 4)
1. Connect all 4 fender brackets to the fenders using 3/8” x 3/4” slot head
screws and nuts. Assemble with the nuts to the inside of the fenders as
shown. No washers here. Fully
tighten all 8 screws and nuts.
Note: fenders are symmetrical
and t on either side of the
trailer.
Install trick shown below
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FENDER ASSEMBLY (Group 4)
1. Connect all 4 fender brackets to the fenders using 3/8” x 3/4” slot head
screws and nuts. Assemble with the nuts to the inside of the fenders as
shown. No washers here. Fully
tighten all 8 screws and nuts.
Note: fenders are symmetrical
and t on either side of the
trailer.
Install trick shown below
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3. Tighten bolts fully and repeat for other side.
Note that when bolting the mounting brackets to the frame you will install
a washer on both sides, under the head of
each bolt and under each nut.
2. Using 3/8” x 1” bolts, washers on both
sides, and nuts, attach the fender brackets
to the slotted holes in the frame as shown.
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1. Installing the ground wire con-
nector. Strip 3/8” of insulation off the
white ground wire and crimp on the
ring connector as shown.
2. Assemble the tongue skid and safety chain assembly
with a 3/8” x 1-1/2” bolt as shown. Use washers above
and below the chain ends.
COUPLER ASSEMBLY
(Group 5)
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1. Assemble the tongue skid and safety chain
assembly with a 3/8” x 1-1/2” bolt as shown.
Use washers above and below the chain ends.
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MPG460G
1. Installing the ground wire con-
nector. Strip 3/8” of insulation off the
white ground wire and crimp on the
ring connector as shown.
2. Assemble the tongue skid and safety chain assembly
with a 3/8” x 1-1/2” bolt as shown. Use washers above
and below the chain ends.
COUPLER ASSEMBLY
(Group 5)
[e-mail]
800-295-0042 ext.215

3. Place the skid and chain as-
sembly under the tongue and
insert the bolt up through the skid
bolt hole on the bottom of the
tongue as shown.
4. Slip the ring terminal over the
bolt and install the nylon lock nut
hand tight.
5. Check that the rear end of the
skid is still in its hole in the bot-
tom of the tongue. Tighten the
bolt while holding the nut station-
ary. This way the ring terminal remains straight.
6. Install the coupler and
coupler handle onto the
tongue as shown. Then
tighten until the coupler
rmly grips the tongue.
Don’t over tighten and crush
the tongue.
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5. Install the coupler and coupler
handle onto the tongue as shown.
Then tighten until the coupler rmly
grips the tongue. Don’t over tighten
and crush the tongue.
NOTE: OVER TIGHTENING WILL
PREVENT THE COUPLER LATCH
FROM FUNCTIONING
PROPERLY.
2. Place the skid and chain
assembly under the tongue and
insert the bolt up through the skid
bolt hole on the bottom of the
tongue as shown.
3. Slip the nylon lock nut over the
bolt and hand tighten.
4. Check that the rear end of the
skid is still in its hole in the bottom
of the tongue. Fully tighten the bolt
and lock nut.
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