Malone XtraLight MPG525G Assembly Instructions Manual

MALONE

R

MALONE

R

*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 pertaining to registering your trailer in a safe spot.

If you encounter any missing components please contact us at:

Email:[e-mail]

OR

Phone:(207) 774 - 9100 X215

Business Hours: Monday-Friday

9am- 5pm

Thank you from all of us at Malone

MPG525

MALONE

R

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# or Serial #

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 XtraLightTM Trailer

MALONE

MALONE

Model MPG525G Assembly Instructions

MPG525G

R

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

1

R

MPG525G

Group 1:
Frame
Components

Bag 11430

Group 2:
Axle / Spring Components

Bag 11432

Visit www.maloneautoracks.com/Replacement-Parts

for all of your spare part needs

Group 3:

MPG460G

COUPLER ASSEMBLY
(Group 5)

Group 3: Lighting Components

MPG525G

Lighting
Components

Group 4: Fender Components

Bag 11468

Group 5: Coupler Components

Bag 11431

Bag 11494

Visit www.maloneautoracks.com/Replacement-Parts

for all of your spare part needs

Bag 11433

Bag 11433

Group 6: Load Bar Components

Load Bars Support Tubes (4)

TONGUE & FRAME ASSEMBLY (Group 1)

1. First we will build the 2 piece tongue. The middle
of the tongue has symmetrical holes for the joining
plates, and You can identify the hitch end of the

tongue by the 3 holes on the left (drivers) side for

the coupler.

2. Align the tongue half’s together and insert the
wiring harness through both sections of the tongue,
making sure the plug end matches the

vehicles connection. The colored pigtails should

be towards the rear of the tongue.

D-Rings (4)

Load Bars (2) and Brackets (4)

Coupler / Hitch End

3. Being careful not to pinch the wiring harness,
square the tongue half ends together and install the
joining plates on each side. (Note the rear tongue

section is symmetrical so it works ne either way. It

has no top and bottom.) Fully tighten the 1/2” bolts
with two 3/4” wrenches.

Visit www.maloneautoracks.com/Replacement-Parts

[e-mail]

4 800-295-0042 ext. 215

for all of your spare part needs

MPG525G

14. Being careful not to pinch the wiring harness, square
the tongue half ends together and install the joining plates
on each side. (Note
the rear tongue section
is symmetrical so it
works fi ne either way.
It has no top and
bottom.) Fully tighten
the 1/2” bolts with two
3/4” wrenches.

NOTE: We begin assembling the frame upside down, later we will fl ip it over to complete the assembly.

MALONE

4. Layout the frame components as shown, “upside down”.

(b) The tongue mounting holes in the middle of the front two cross members must face up.
(c) The MALONE decal is on the rear cross member and must be upside down.

(d) The mid-cross member must face the same way as the rear cross member.

(e) Spring hangers with shackle bolt holes to the front, slippers to the back.
(f) Carriage bolts to mount cross members to rails.

(g) Regular bolts to mount spring hanger brackets.

15. Layout the frame components as shown, “upside down”.
(a) The spring bracket mounting holes in the side rails must face up.
(b) The tongue mounting holes in the middle of the front two cross members must face up.
(c) The MALONE decal is on the rear cross member and must be upside down.
(d) The mid-cross member must face the same way as the rear cross member.
(e) Spring hangers with shackle bolt holes to the front, slippers to the back.
(f) Carriage bolts to mount cross members to rails.
(g) Regular bolts to mount spring hanger brackets.

(a) The spring bracket mounting holes in the side rails must face up.

a

e

a

d

d

b

b

c

a

e

a

g

5. Install all 12 carriage bolts, nger tighten only. Install all 8 spring hanger bolts with the nuts inside the

frame. Fully tighten the rear spring hangers. Finger tighten the front spring hangers.

6. Lay the tongue onto the
frame, with the MALONE
logo upside down.

Support the end of the
tongue so it lays nearly

at on the front and mid

cross members.

f

[e-mail]

800-295-0042 ext. 215

5

R

MPG525G

17. Lay the tongue onto the frame, with the MALONE logo upside down. Support
the end of the tongue so it lays nearly fl at on the front and mid cross members.

18. Install the long 1/2” bolt through the front cross member, (washer under the bolt head), nut inside
the cross member
and fi nger tighten.
Install the short 1/2”
bolt inside the end of
the tongue, (washer
under the bolt head),
nut inside the cross
member and fi nger
tighten.

19. Fully tighten all
12 carriage bolts.
Then fully tighten
the two 1/2” tongue
mounting bolts.

7. Install the long 1/2” bolt through the front cross member, (washer under the bolt head), nut inside the

MALONE

cross member and nger tighten. Install the short 1/2” bolt inside the end of the tongue, (washer under the
bolt head), nut inside the cross member and nger tighten

8. Fully tighten all 12 carriage bolts. Then fully tighten the two 1/2” tongue mounting bolts.

SPRING AND AXLE ASSEMBLY

SPRING & AXLE ASSEMBLY (Group 2)

(Group 2)

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

2. Find the side of the axle
with the spring centering
holes. These holes mate
with the spring center stud.

4. Run each nut down UNTIL IT NEARLY TOUCHES
THE PLATE ONLY! DON’T FULLY TIGHTEN NOW!!
You may need to wiggle the springs to fi t them into the
spring brackets in the next step.

6 800-295-0042 ext. 215

R

[e-mail]