Malone XtraLight MPG525G Assembly Instructions Manual

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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 pertaining to registering your trailer in a safe spot.

If you encounter any missing components please contact us at:

Email:technical@maloneautoracks.com

Phone:(207) 774 - 9100 X215

Business Hours: Monday-Friday

9am- 5pm

Thank you from all of us at Malone

MALONE

MPG525

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Summary of Contents for Malone XtraLight MPG525G

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 pertaining to registering your trailer in a safe spot.
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 XtraLight Trailer Malone MicroSport Trailer Model MPG525G 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 MPG525G Group 1: Frame Bag 11430 Components Group 2: Bag 11432 Axle / Spring Components Visit www.maloneautoracks.com/Replacement-Parts technical@maloneautoracks.com 800-295-0042 ext 206 for all of your spare part needs...
Page 5 MPG525G Group 3: Group 3: Lighting Components Lighting Bag 11468 Components Group 4: Fender Components Bag 11431 COUPLER ASSEMBLY MPG460G (Group 5) Group 5: Coupler Components Bag 11494 Visit www.maloneautoracks.com/Replacement-Parts technical@maloneautoracks.com 800-295-0042 ext 206 for all of your spare part needs 1.
Page 6 Group 6: Load Bar Components Load Bars Support Tubes (4) D-Rings (4) ASSEMBLY (Group 1) FRAME ASSEMBLY (Group 1) Load Bars (2) and Brackets (4) will build the 2 piece tongue. The middle of the 1. First we will build the 2 piece tongue. The middle of the symmetrical holes for the joining plates.
Page 7 (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. (c) The MALONE decal is on the rear cross member and must be upside down.
Page 8 7. Install the long 1/2” bolt through the front cross member, (washer under the bolt head), nut inside the MPG525G 17. Lay the tongue onto the frame, with the MALONE logo upside down. Support cross member and finger tighten. Install the short 1/2” bolt inside the end of the tongue, (washer under the the end of the tongue so it lays nearly ﬂ...
Page 9 TO ASSIST YOU. 11. Tighten the lug nuts ﬁ rmly, to 75 to 11. Tighten the lug nuts ﬁ rmly, to 75 to 85 foot pounds of torque. 85 foot pounds of torque. MALONE technical@maloneautoracks.com technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext 206 800-295-0042 ext 206 800-295-0042 ext.
Page 10 ” of wire past ngers to pull MALONE technical@maloneautoracks.com 800-295-0042 ext. 215 to the quick connector as shown. Then e marker...
Page 11 ﬁ t the fender. Use hex bolts with the nuts inside the frame. 2. Install and fully tighten fender. Use screws and nuts, nuts inside fender. 3. Fully tighten fender mounting brackets. MALONE technical@maloneautoracks.com technical@maloneautoracks.com 800-295-0042 ext. 215 800-295-0042 ext 206...
Page 12 4. Install the load bars and brackets onto the load bar supports. Center the load bars and fully tighten all load bar bolts. 5. Use a small hammer or block of wood to install the end caps onto the load bars. MALONE technical@maloneautoracks.com 800-295-0042 ext. 215...
Page 13 MPG525G 2. Use a small hammer or block of wood to install the end plugs into both ends of all four load bar support tubes. 3. Install the load bar support tubes onto the outer most pair of holes in the front and rear cross member and fully tighten.
Page 15 MALONE Trailer Checklist & Maintenance Manual MPG525G XtraLight MPG460G MicroSport MPG535G MegaSport MALONE MPG570G Sherpa...
Page 17 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 19 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 20 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 21 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 22 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 23 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 24 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 25 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.

This manual is also suitable for:

Xtralight mpg525 Microsport mpg460g Megasport mpg535g Sherpa mpg570g