Malone MPG460G Assembly Instructions Manual

MPG460G

REV 3

Malone MicroSport Trailer

TM

Model MPG460G 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 fl at 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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MPG460G

Group 1:
Frame
Components

Bag 11462

Group 2:
Axle / Spring
Components

Bag 11476

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MPG460G

Group 3: Lighting Components

Group 4:
Fender Components

Bag 11468

Bag 11464

Group 5: Coupler Components

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Bag 11494

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MPG460G

Group 6:
Load Bar
Components

Bag 11489

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FRAME ASSEMBLY (Group 1)

1. We assemble the frame on its back to make it easier to install the springs
and axle. Once the springs and axle assembly is installed we will fl ip the trailer
over to complete the assembly. So fi rst, layout the frame components upside
down as shown. The spring bracket mounting holes should be facing up. All
the decals should be upside down.

MPG460G

2. Attach the spring
hanger brackets to the
frame. 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.

3. Identify the hitch end of the tongue
by the 3 holes on the left side. Insert
the small wire protection grommet
into the lower hole where shown,
then push it all the way in till it snaps
in place.

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MPG460G

4. Pass the wiring harness into
the grommet and out the front
end of the tongue as shown.
Stretch out the white wire and
leave an equal length of the
green/brown/yellow wire outside
the grommet as shown. This
length of wires will be the con­nector to your tow vehicle.

5. Roll this wire so it
doesn’t get accidentally
pulled inside the tongue.

6. Now its time to pass the wire ends thru the tongue.
Make sure the wires are tangle free, then attach a
weight to the end of the wires. A large socket works
great as shown or you could tape a big bolt to the
wires. Tip the tongue up and let gravity work for you.

Feed the wire and let the weight slide through the
tongue pulling the wires with it.

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7. Installing the rear tongue support
bracket. First we lay the tongue back in its
place making sure its upside down. Push
the large wire protection grommet into the
rear tongue support bracket hole, then
pass the wires through the grommet. In­stall the 4-1/2” long x 1/2” bolt up from the
bottom through the tongue support and tongue. Be careful not to pinch the
wires. Add a washer and nut. Hand tighten only.

MPG460G

8. Bolt the tongue support to the frame
rails using 3/8” x 1” carriage head bolts.
Note the square heads go on the outside
with the square holes in the frame. As­semble with washers and nuts on the
inside. Hand tighten only.

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MPG460G

9. Clamp the frame rails around the
tongue as shown using two 1/2” x
3-1/4” bolts. Use a washer on both
sides. Hand tighten only.

10. Lay the two frame cross members
in between the frame rails. The two
holes in the middle should face DOWN
as shown. Bolt the frame rails to the
cross members using 3/8” x 1” carriage
bolts and nuts, (no washers). The square carriage heads go
to the outside with the square holes in the frame rails. Hand
tighten only.

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11. TIME TO TIGHTEN

FRAME BOLTS: Its important to

follow this tightening sequence in order
to insure the trailer will be straight after
everything is tight.

A) Tighten the 8 nuts holding the ends
of the two cross members.

MPG460G

B) Tighten the rear tongue support bracket. Check that
you installed washers under the 4 nuts as shown. Evenly
tighten the 4 nuts.

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C) Tighten the two tongue bolts
snug to the frame rails.

DON”T overtighten, you will just
crush the tongue.

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MPG460G

D) Tighten the big bolt thru the rear
of the tongue and tongue
support. Not too tight, don’t
crush the tongue or support.

Your frame assembly is now complete and should look like this.

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SPRING AND AXLE ASSEMBL Y
(Group 2)

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

MPG460G

2. Spin the axle to fi nd the side with the spring
centering holes. These holes mate with the spring
center stud (shown to the left)

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MPG460G

4. Run each nut down UNTIL IT

TOUCHES THE PLATE ONLY!
DON’T TIGHTEN !!

You will need to wiggle the
springs to fi 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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8. Wiggle the spring eyes into the front hanger brack­ets 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.

9. Now that the axle assembly is at­tached to the frame, tighten the axle
plate U-bolts evenly until there is a
slight bend in the tie plates.

10. Slip the hub caps thru the wheels
from the back then mount the wheels
onto the hubs and hand tighten the lug
nuts.

MPG460G

11. Stand behind the trailer, lift
the rear cross member at one
corner and fl ip the trailer over onto
the tires.

ALWAYS BEND FROM YOUR
KNEES WHEN LIFTING. IF THE
TRAILER IS TOO HEAVY FOR
YOU TO FLIP
SAFELY GET
SOME FRIENDS
TO ASSIST
YOU.

12. Tighten
the lug fi rmly
to 75 to 85 foot
pounds
of torque.

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MPG460G

LIGHT ASSEMBLY (Group 3)

REFERENCE:
Trailer Wiring Color Code

•Brown = running lights

•Yellow = left turn / left brake

•Green = right turn / right brake

•White = ground

1. Attach the tail lamp brackets to
the frame as shown using 3/8” x 1”
carriage head bolts and nuts. No
washers are needed.

2. Sandwich the license plate mounting
bracket between the left side lamp and the
left side tail lamp bracket. Attach the tail
light using the nuts provided with the lamp
kit. Then mount the right side lamp.

3. Use the holes just above the
spring bracket to mount the amber
side lamps. Put the stud through
the forward hole and the wire
through the rear hole. Tuck the wire
so the lamp sits fl ush on the frame.

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4. Check that the coil of wiring harness outside the tongue grommet is still full length.

5. Route the
GREEN/BROWN wire along the
RIGHT side of the frame.
Route the YELLOW/BROWN wire
along the LEFT as shown.

6. Use the clips provided to secure the wire to
the inside of the frame channel as shown

MPG460G

7. Route the wires thru the mid cross member as shown then secure the har­ness in place using the frame clips provided. Use your knife to CAREFULLY
divide 1/2” of the green/
brown wire and the
yellow brown wire just
below the side lamp as
shown.

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8. Then grasp either side of the cut with your fi ngernails
and pull to separate 3” of wire as shown.

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MPG460G

9. Press the brown wire into the quick connector
as shown. Then insert the wire from the side
marker light fully into the 2nd opening. Use pliers
to squeeze the conductor blade down and thru
the insulation. The blade cuts thru the insulation
and connects the wires inside. Flip the cover to
lock the connector. Repeat on the other side again
using the brown wire.

10. Route the harness wires to
the tail lights along the frame.
Use wire clips to secure the wires.

11. Pass the lamp wires inward
through the hole under the tail
lamp mounting bracket.

12. Cut the harness wires off with 10” extra
working length at the tail lamp wires.

13. Strip 1/2” of insulation off the ends of all
tail light wires.

14. Using your fi ngers, twist together
in a clockwise motion the lamp
wire and harness wire, of the the
same color. Carefully screw the
wire nut over the twisted copper in
a clockwise rotation. The threads
inside the wire nut will grip the wires
together. Repeat for all four wires.

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FENDER ASSEMBLY (Group 4)

MPG460G

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 fi t on
either side of the trailer.

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MPG460G

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.

4. 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.
NOTE you will use the center hole in the
bracket and the outside two slotted holes in
the frame.

5. Tighten bolts fully and repeat for other side.

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COUPLER ASSEMBLY
(Group 5)

MPG460G

1. Installing the ground wire con­nector. 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.

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MPG460G

3. 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.

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
bottom of the tongue. Tighten
the bolt while holding the nut
stationary. This way the ring terminal remains straight.

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6. Install the coupler and
coupler handle onto the
tongue as shown. Then
tighten until the coupler
fi rmly grips the tongue.
Don’t over tighten and crush
the tongue.

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LOAD BAR ASSEMBLY (Group 6)

MPG460G

1. Attach a load

bar support tube
onto the rear cross
member. Center
the support tube
on the trailer and
tighten.

2. Attach the second support tube 48 inches forward.
Measure 48 inches on both sides of the trailer to be sure
the load bar is on straight and centered, then tighten the
U-bolts.

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MPG460G

3. Use your hammer and carefully
pound the end plugs into the ends of the
support tubes.

4. Slip the load bar brackets over

the load bars (as shown) and loosely
install the two small carriage bolts /
nuts through each bracket trapping
the load bars inside the brackets.

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5. Install and hand tighten the bolts holding
each bracket to the support tube.

MPG460G

6. Center the load bars to the trailer, then tighten all 12 bracket bolts

7. Go back now and re-check that all nuts and bolts
on the ENTIRE trailer are securely tightened.

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MPG460G

Apply the TIRE AND LOADING Decal and the VIN Decal as shown below, onto

the left side of the frame. Be sure to clean the frame before applying the decals.

Your MicroSport Trailer is now complete and ready to register and title !

TM

Contact your local DMV offi ce for specifi c procedures in your State.

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for more fi ne products and accessories.

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