Malone MPG460G 2010 User Manual

MPG460G

TM

Malone MicroSport Trailer

01-2010

Model MPG460G Assembly Instructions

Take a few moments now and read through these instructions.

Familiarize yourself with the step by step assembly process before you

begin turning wrenches. Un-pack and sort the components into groups as

shown in the following photos. Then you will assemble each group in order.

Lets get started !!

Required Tools:

• 3/4” wrenches (2) • 9/16” wrenches (2) a 9/16” deep socket is very handy.

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

• Razor knife • Pliers

• Wire stripping tool • Electrical connector crimping tool

• Lug wrench • Small hammer

Visit us at

maloneautoracks.com

for more ne products and accessories.

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MPG460G

Group 1:
Frame
Components

01-2010

Bag 11462

Group 2:
Axle / Spring
Components

Bag 11467

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01-2010

Group 3: Lighting Components

Group 4:

Bag 11464

Fender Components

Bag 11468

Group 5: Coupler Components

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Bag 11494

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MPG460G

Group 6:
Load Bar
Components

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Bag 11497

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MPG460G

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 ip the trailer
over to complete the assembly. So 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.

01-2010

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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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.

01-2010

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.

01-2010

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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