Malone MPG460XT User Manual

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800-295-0042 ext 206
1
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 at blade screw driver • (1) 7/16” wrench
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.
Malone MicroSport Trailer
Model MPG460XT Assembly Instructions
TM
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Summary of Contents

Page 1 - Malone MicroSport Trailer

800-295-0042 ext [email protected] a few moments and read through these instructions to familiarize yourself with the step

Page 2 - Bag 11462

MPG460XT800-295-0042 ext [email protected]. Wiggle the spring eyes into the front hanger brackets and bolt using 1/2” x 3” bolts an

Page 3 - Group 5: Coupler Components

800-295-0042 ext [email protected]. Tighten the lug fi rmly to 75 to 85 foot pounds of torque.11. Slip the large U-bolt in

Page 4 - Components

MPG460XT800-295-0042 ext [email protected]. Install the wiring harness extension thru the tongue. The easiest way is to let gravi

Page 5

800-295-0042 ext [email protected]:Trailer Wiring Color Code•Brown = running lights•Yellow = left turn / left brake•

Page 6

MPG460XT800-295-0042 ext [email protected]. Routing the wiring harness.- Route the GREEN/BROWN wire along the RIGHT side of the fr

Page 7

800-295-0042 ext [email protected]. Connecting the side lamps. To control cutting between two conductors without dam-aging

Page 8 - (Group 2)

MPG460XT800-295-0042 ext [email protected]. There are holes in the back side of each lamp marked by wire color. - Identify which

Page 9

800-295-0042 ext [email protected] ASSEMBLY (Group 4)1. Connect all 4 fender brackets to the fenders using 3/8” x 3/4”

Page 10 - 800-295-0042 ext 206

MPG460XT800-295-0042 ext [email protected]. Tighten bolts fully and repeat for other side.Note that when bolting the mounting brack

Page 11

800-295-0042 ext [email protected]. Installing the ground wire con-nector. Strip 3/8” of insulation off the white ground w

Page 12

Bag 11491MPG460XT800-295-0042 ext [email protected] 1: Frame ComponentsBag 11462Group 2: Axle / Spring ComponentsBag 11476

Page 13 - LIGHT ASSEMBLY (Group 3)

MPG460XT800-295-0042 ext [email protected]. Place the skid and chain as-sembly under the tongue and insert the bolt up through the s

Page 14

800-295-0042 ext [email protected] BAR ASSEMBLY (Group 6)1. Attach a load bar support tube onto the rear cross member.

Page 15

MPG460XT800-295-0042 ext [email protected]. Use your hammer and carefully pound the end plugs into the ends of the support tubes.

Page 16

800-295-0042 ext [email protected]. Center the load bars to the trailer, then tighten all 12 bracket bolts.7. Go back now

Page 17 - FENDER ASSEMBLY (Group 4)

MPG460XT800-295-0042 ext [email protected] us at maloneautoracks.com for more fi ne products and accessories.To use the retractab

Page 18

800-295-0042 ext [email protected] 4: Fender ComponentsBag 11464Group 3: Lighting ComponentsBag 11468Group 5: Coupler Com

Page 19 - (Group 5)

MPG460XT800-295-0042 ext [email protected] ASSEMBLY (Group 1)1. We assemble the frame on its back to make it easier to install th

Page 20

800-295-0042 ext [email protected]. Attach the spring hanger brackets to the frame. The U shaped shackle bolt brackets mount

Page 21 - LOAD BAR ASSEMBLY (Group 6)

MPG460XT800-295-0042 ext [email protected]. Install the clip nut as shown on the end of the short piece of 2x3 tub-ing. Note, the pa

Page 22 - 4. Slip the load bar

800-295-0042 ext [email protected]. Bolt the tongue support to the frame rails using 3/8” x 1” carriage head bolts. Note t

Page 23

MPG460XT800-295-0042 ext [email protected] AND AXLE ASSEMBLY (Group 2)2. Spin the axle to fi nd the side with the spring center

Page 24

800-295-0042 ext [email protected]. Run each nut down but,ONLY UNTIL THE NUTS ALMOST TOUCH THE PLATE !!You will need lots of

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