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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 in a safe spot.
If you encounter any missing components please contact us at:
Email:technical@maloneautoracks.com
OR
Phone:(207) 774 - 9100 X215
Business Hours: Monday-Friday
9am- 5pm
Thank you from all of us at Malone
MALONE
R
MPG550LB
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Summary of Contents for Malone MegaSport MPG550LB
- Page 1 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:technical@maloneautoracks.com...
- Page 2 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.
- Page 3 MPG460XT REV 2 Malone MegaSport Trailer Malone MicroSport Trailer Model MPG550LB Assembly Instructions Model MPG460XT Assembly Instructions Take a few moments and read through these instructions to familiarize yourself Take a few moments and read through these instructions to familiarize yourself with the with the step by step assembly process before you begin turning wrenches.
- Page 4 Group 1: Bag 11412 Frame Components Main Frame Tongue Frame Group 2: Axle / Spring Components Bag 11412-1 Visit www.maloneautoracks.com/Replacement-Parts technical@maloneautoracks.com 800-295-0042 ext 215 for all of your spare part needs...
- Page 5 Bag 11468 Group 3: Lighting Components Group 4: Bag 11464 Fender Components Group 5: Coupler Components Bag 11494 Visit www.maloneautoracks.com/Replacement-Parts technical@maloneautoracks.com 800-295-0042 ext 215 for all of your spare part needs...
- Page 6 Group 6: Load Bar Components Group 7: Jack Stand Visit www.maloneautoracks.com/Replacement-Parts for all of your spare part needs...
- Page 7 The spring bracket mounting holes should be facing up. All the decals should be upside down. MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 8 Working your way forwards, the side rails will pinch together at the tongue. You’ll use washers on front 2 cross members utilizing the larger oval holes. MALONE technical@maloneautoracks.com 800-295-0042 ext.215...
- Page 9 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. technical@maloneautoracks.com 800-295-0042 ext 215 MALONE technical@maloneautoracks.com 800-295-0042 ext.215...
- Page 10 “slipper” brack- ets 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. MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 11 2. Spin the axle to find the side with the spring centering holes. These holes mate with the spring center stud (shown to the left) MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 12 5. Lift the axle/spring assembly to the trailer frame and slide the slipper spring ends into the slipper spring brackets as shown. MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215...
- Page 13 ALWAYS BEND FROM YOUR KNEES WHEN LIFTING. THIS TRAILER IS HEAVY TO FLIP SAFELY ALONE, GET SOME FRIENDS TO ASSIST YOU. 10. Tighten the lug nuts firmly to 75 to 85 foot pounds of torque. MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 14 11. With the trailer now turned right-side up, go back and fully tighten all bolts and nuts along the frame rails and cross members from Step LIGHT ASSEMBLY (Group 3) L.E.D. REFERENCE: Trailer Wiring Color Code •Brown = running lights •Yellow = left turn / left brake •Green = right turn / right brake •White = ground...
- Page 15 GREEN/BROWN/WHITE wire along the passengers side. Route the YELLOW/BROWN/WHITE along the drivers side as shown. 6. Next, we’ll route the wires through the cross members, One lead at a time, all the way through the trailer to the tail lights. MALONE technical@maloneautoracks.com 800-295-0042 ext.215...
- Page 16 8. Use the clips provided to secure the wire to the inside of the frame channel as shown. NOTE: THESE UNUSED PLUGS ARE FOR AUXILIARY ACCESSORIES LIKE THE MALONE MPG543 CHARGING UNIT AND/OR MPG539 FLOOD LIGHT (NOT INCLUDED) MPG543 MPG539 MALONE technical@maloneautoracks.com...
- Page 17 Note: fenders are symmetrical and fit on either side of the and fit on either side of the trailer. trailer. Install trick shown below Install trick shown below technical@maloneautoracks.com 800-295-0042 ext 215 technical@maloneautoracks.com MALONE technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 18 2. 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. 3. Tighten bolts fully and repeat for other side. MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215...
- Page 19 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. technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 206 800-295-0042 ext.215 MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 20 Don’t over tighten tighten until the coupler and crush the tongue. firmly grips the tongue. Don’t over tighten and crush the tongue. NOTE: OVER TIGHTENING WILL PREVENT THE COUPLER LATCH FROM FUNCTIONING PROPERLY. MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 21 8. Go back now and re-check that all nuts and bolts on the ENTIRE trailer are securely tightened. 8. Go back now and re-check that all nuts and bolts on the ENTIRE trailer are securely tightened. technical@maloneautoracks.com 800-295-0042 ext 215 MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 22 Load Bar Components (Group 6) NOTE: The curved upright supports will not be used for this build. (not pictured) MALONE technical@maloneautoracks.com 800-295-0042 ext.215...
- Page 23 MALONE technical@maloneautoracks.com 800-295-0042 ext.215...
- Page 24 MALONE technical@maloneautoracks.com 800-295-0042 ext.215...
- Page 25 MALONE technical@maloneautoracks.com 800-295-0042 ext.215...
- Page 26 MALONE technical@maloneautoracks.com 800-295-0042 ext.215...
- Page 27 Your MegaSport Trailer is now complete and ready to register and title ! Contact your local DMV office for specific procedures in your State. maloneautoracks.com Visit us at for more fine products and accessories. MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 215 800-295-0042 ext.215...
- Page 29 MALONE Trailer Checklist & Maintenance Manual MPG525G XtraLight MPG460G MicroSport MPG535G MegaSport MALONE MPG570G Sherpa...
- Page 31 Congratulations on your new Malone trailer! Take a couple minutes to read through this manual for commonly asked questions and some basic trailer maintenance that will ensure your trailer is preforming at its best. And as always please free to contact us with any questions you may have.
- Page 33 Some trailers now have an integrated ‘zerk’ on the backside of the hub. For the customer it means they can do periodic grease “freshenings” without disassembly of the hubs. Procedure for hub with integrated zerk fitting: Prepare a disposable container for the old grease to fall into. Remove the wheel and dust cap.
- Page 34 Adding your own Zerk fitting to avoid the previous steps above: You can add your own zerk fitting to the front of your hub by adding a Bearing Buddy ® Protector. Look for Model# 1980A and follow the manufactures instructions for use. Type of grease to use: Automotive bearing grease is OK in a pinch, marine wheel-bearing grease is better, and synthetic marine-wheel bearing grease is best.
- Page 35 Damaged Bearings? Replace them right away. Continued Procedure: Continued Install the grease seal. Don’t hammer directly on the seal. Use a block of wood. Take care to drive the seal in straight. Seal should be flush to the outside surface of the hub. Fill the hub, in behind the seal, with grease then slide the hub over the spindle being careful not to damage the seal against the spindle.
- Page 36 Towing Speeds/Tips: The hubs on your trailer are already fulled packed with a high-speed, high-temp grease, safely tow at any posted speed limit. Including highway speeds. allowing you to You need to allow for extra time and room when switching lanes, stopping, and passing other vehicles when towing a trailer.
- Page 37 Electrical/Lighting Properly functioning trailer lights are a must for safety, so check your lights every time you use your trailer. Some problems, such as a burned-out bulb or a bad ground wire, can be a snap to fix—others can be a real pain to diagnose and repair. Wiring Diagram For Trailer Lights Trailer Wiring Assembly Note: Wiring colors are the same from incandescent lights and LED light kits.
- Page 38 Electrical/Lighting Continued We can’t cover every scenario in this manual but here’s some trouble shooting we can do to help get your trailer back in top condition. Having a helper standing behind the vehicle to see if the lights are working will make the process go a lot quicker..and save you from running back and forth.
- Page 39 If the original retail purchaser is unable to contact the Malone dealer, or the dealer is not able to remedy the defect, the original retail purchaser should contact Malone by email at technical@maloneautoracks.com.
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