Malone MegaSport MPG550LB Installation Manual

MALONE

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MALONE

*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:[e-mail]

OR

Phone:(207) 774 - 9100 X215

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Business Hours: Monday-Friday

9am- 5pm

Thank you from all of us at Malone

MPG550LB

MALONE

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Important Note

Product Warranty & Registration Form

All information is condential and used exclusively by MALONE only.

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: [e-mail]

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

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 fl at blade screw driver • (1) 7/16” wrench

• Razor knife • Pliers

• Wire stripping tool • Electrical connector crimping tool

• Lug wrench • Small hammer

Malone MicroSport Trailer

Model MPG460XT Assembly Instructions

TM

REV 2

Malone MegaSportTM Trailer

MALONE

MALONE

Model MPG550LB Assembly Instructions

MPG550LB

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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.

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

Then assemble each group in order. Lets get started !!

• Large Phillips head screw driver • Rubber hammer

Visit us at maloneautoracks.com

for more fi ne products and accessories.

[e-mail]

800-295-0042 ext. 215

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Group 1:
Frame
Components

Main Frame

Bag 11412

+

Group 2:
Axle / Spring
Components

Tongue Frame

Bag 11412-1

Visit www.maloneautoracks.com/Replacement-Parts

for all of your spare part needs

Group 3: Lighting Components

Bag 11468

Group 4:
Fender Components

Group 5: Coupler Components

Bag 11464

Bag 11494

Visit www.maloneautoracks.com/Replacement-Parts

for all of your spare part needs

Bag 11412-2

Group 6:
Load Bar
Components

x4

x4

Group 7:

Jack Stand

Visit www.maloneautoracks.com/Replacement-Parts

for all of your spare part needs

MAIN FRAME ASSEMBLY (Group 1)

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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.

Securing four corners

spring bracket mounting
holes

The spring bracket mounting holes
should be facing up. All the decals
should be upside down.

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TONGUE ASSEMBLY (GROUP 1)

MALONE

3. Identify the hitch end of the tongue by the 3

holes on the left (drivers) side.

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.

5. Add the tongue safety bolt at the non-coupler end as pictured.

NOTE: Wires removed for clarity

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6. Begin attaching the tongue components with the side frame

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rails rst, then the tongue down the middle.

8. Begin attaching the tongue components with the side frame

Tighten the side rails beginning at the 4th cross member

rails rst, then the tongue down the middle.

back, going through both the main frame rail and the cross

member, joining them together. Working your way forwards,

Tighten the side rails beginning at the 4th cross member back,

the side rails will pinch together at the tongue. You’ll use

going through both the main frame rail and cross member,

washers on the front 2 cross members utilizing the larger oval

joining them together. Working your way forwards, the side

holes.

rails will pinch together at the tongue. You’ll use washers on

front 2 cross members utilizing the larger oval holes.

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7.

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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.

8.

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” brack­ets 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.

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SPRING AND AXLE ASSEMBLY

MALONE

(Group 2)

1. Set the envelope containing the manufacturer’s
certicate of origin (MCO) and VIN labels aside in a

safe place.

*Set the large red envelope

(in the axle box) containing

important documents in a safe spot.

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)

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4. Run each nut down UNTIL IT

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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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