Malone MPG460XT User Manual

MPG460XT

Malone MicroSport Trailer

TM

Model MPG460XT 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

for more fi ne products and accessories.

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MPG460XT

Group 1:
Frame
Components

Bag 11491

Bag 11462

Group 2:
Axle / Spring
Components

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Bag 11476

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MPG460XT

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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MPG460XT

Group 6:
Load Bar
Components

Bag 11489

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 all be upside down.

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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.

MPG460XT

3. Lay the two frame cross mem­bers in between the frame rails. The
two holes in the middle should face
DOWN as shown. Channels face
each other.

4. 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. Leave the nuts loose until after all bolts
are installed. Then we will tighten everything
at once in a later step.

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5

MPG460XT

5. Install the clip nut as
shown on the end of the
short piece of 2x3 tub­ing. Note, the parts are
symetrical so it doesn’t
matter which way they
are turned. Then fi t the
rear tongue support
bracket over the clip nut
and install a short bolt
and washer. Hand tight
only. Now fl ip the rear
tongue support assembly
over so the bolt head on the bottom.

6. Slide the rear tongue support assembly, bolt head down, in between
the frame rails as shown.

7. Set the retractable tongue box onto the frame as shown.

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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. Don’t fully
tighten.

9. Install the 1/2” x 3-1/4” bolts with washers on both sides thru the
retractable tongue
box.

MPG460XT

Don’t fully tighten.

10. FRAME BOLT TIGHTENING: Starting at the rear corners of the frame and fully
tighten each bolt, working to the front, fully tighten all frame bolts ending with the
1/2” bolts thru the retractable tongue box. You don’t have easy access to tighten the
rear tongue support bolt until after you fl ip the trailer over.

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MPG460XT

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.

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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