Two-wheeled motor vehicle

Abstract

To provide a two-wheeled motor vehicle assembly in which modern electrical components are mounted in a package and wires and electrical components with modern characteristics can be hidden so as not to be seen.SOLUTION: A two-wheeled motor vehicle includes: a first frame member 110 including a first opening portion 128; and a plurality of wires. A joint member 140 is coupled to the first frame member 110 and at least a second frame member. The joint member 140 includes a second opening portion inside the joint member 140. The plurality of wires extend through the first frame member 110 and the second opening portion of the joint member 140 to the first opening portion 128.SELECTED DRAWING: Figure 6A

Description

[Technical field]

[0001] The present disclosure relates to motorcycles, and more particularly, to frames and structural assemblies for motorcycles. [Background technology]

[0002] This section provides background information related to the present disclosure that is not necessarily prior art.

[0003] Motorcycle designs have been around since the late 1800s, with retro-style motorcycles from the mid-1900s being popular among motorcycle enthusiasts.

[0004] Although retro style motorcycles are popular, motorcycle enthusiasts are also familiar with many modern aspects of automobile vehicles. Electronic features such as navigation, anti-lock braking, and other features are also desirable to motorcycle enthusiasts. The complexity of implementing such features is complex. Various wire harnesses and fluid hoses are used to provide various functions. Providing many modern features requires that a significant amount of electronic circuitry be incorporated into the vehicle body. When modern feature wires and electronic components are incorporated into the motorcycle, it is difficult to maintain the retro styling of the vehicle body. Summary of the Invention [Means for solving the problem]

[0005] This section provides a general overview of the disclosure and is not an exhaustive disclosure of its entire scope or all of its features.

[0006] The present disclosure provides a motorcycle assembly that allows for modern electrical components to be incorporated into a package that hides such components from view.

[0007] In one aspect of the disclosure, a motorcycle includes a first frame member having a first opening and a plurality of wires. A joint member is coupled to the first frame member and at least a second frame member. The joint member has a second opening therein. The plurality of wires extend through the first frame member and the second opening in the joint member to the first opening.

[0008] In another aspect of the present disclosure, a motorcycle has a first frame member and a second frame member. The first frame member is spaced from the second frame member. A first hand brake is disposed on the handlebar. A brake manifold is coupled to the first frame member and coupled to a first brake line extending from the first frame member. The first brake line is separable from the brake manifold.

[0009] In yet another aspect of the disclosure, a motorcycle includes a first fork, a second fork spaced apart from the first fork, a first triple clamp coupled between the first and second forks, and a second triple clamp coupled between the first and second forks. A first grommet disposed on the first fork adjacent to the second triple clamp. The first grommet has a first spacer flange extending from the first grommet. A second grommet disposed on the second fork adjacent to the second triple clamp. The second grommet has a second spacer flange extending from the second grommet.

[0010] In a further aspect of the disclosure, a motorcycle has a first cross rail and a second cross rail spaced apart from the second cross rail. An elongated swing arm includes a first arm and a second arm. The swing arm has a first end and a second end. The first end includes a first cross member and a second cross member. The first cross member is hollow and sized to receive a fastener that rotatably joins the swing arm to the first cross rail and the second cross rail. A first shock absorber is coupled to the second end of the first arm and a second shock absorber is coupled to the second end of the second arm.

[0011] Further areas of applicability will become apparent from the description provided herein.The description of the present invention and specific examples are intended as merely illustrative and are not intended to limit the scope of the present disclosure.

[0012] The drawings described herein are intended to illustrate only selected embodiments rather than all possible implementations and are not intended to limit the scope of the present disclosure. [Brief description of the drawings]

[0013] [Figure 1A] FIG. 1 is a perspective view of a first example of a motorcycle. [Figure 1B] FIG. 1B is a right side view of the motorcycle of FIG. 1A. [Figure 1C] FIG. 1B is a left side view of the motorcycle of FIG. 1A. [Figure 1D] FIG. 1B is a lower front perspective view of the left side of the motorcycle of FIG. 1A. [Figure 1E] FIG. 13 is a left side view of the second design of the motorcycle. [Figure 2A] FIG. [Figure 2B] FIG. [Figure 2C] FIG. [Figure 2D] FIG. [Figure 2E] An enlarged view of the front engine mount and head casting 130. [Figure 3A] FIG. 2 is a left side view of the engine of the motorcycle. [Figure 3B] FIG. 4 is an enlarged view of the rear motor mount. [Figure 4A] FIG. 2 is a partial right side perspective view of the motorcycle with some of the components removed. [Figure 4B] FIG. 4B is a close-up view of the fork coupled to the triple clamp of FIG. 4A. [Figure 4C] FIG. 2 is a detailed perspective view of the upper part of the forks for the lighting assembly at the front of the vehicle body. [Figure 4D] FIG. 1 is an underside view of the lower triple clamp. [Figure 4E] FIG. 1 is a perspective view of the lower triple clamp coupled to the fork cover. [Figure 4F] FIG. 1 is a partial assembly view of the upper part of the fork relative to the triple clamp. [Figure 4G] FIG. 2 is a perspective view of a clamp for the upper part of the fork; [Figure 4H] FIG. 4H is a perspective view of the clamp of FIG. 4G partially assembled on the top of the fork. [Figure 4I] FIG. 2 is a partial perspective view of the upper part of the fork. [Figure 4J] FIG. 4H is a perspective view of the upper part of the fork with the triple clamp and the clamp of FIG. 4G attached. [Figure 4K] FIG. [Figure 4L] FIG. 4K is a perspective view of the nacelle mounted on top of the forks. [Figure 4M] FIG. 4H is a close-up perspective view of the top of the upper triple clamp for the front nacelle and the clamp of FIG. [Figure 4N] FIG. 1 is a rear side perspective view of the upper portion of the fork with the rear nacelle portion. [Figure 4O] FIG. [Figure 4P]FIG. 1 is a perspective view of a fog lamp attached to the front of a motorcycle. [Figure 5A] FIG. 1 is a front view of a motorcycle equipped with a windscreen. [Figure 5B] FIG. 2 is a partial perspective front view of a windscreen mount at the front end of the vehicle body. [Figure 6A] FIG. 2 is a cross-sectional view of the fuel tank 82 mounting system. [Figure 6B] FIG. 1 is a perspective view of a fuel tank showing the internal mounting system. [Figure 6C] 4A and 4B are side and perspective views of a fuel tank mount; [Figure 6D] 4A and 4B are side and perspective views of a fuel tank mount; [Figure 6E] 4A and 4B are side and perspective views of a fuel tank mount; [Figure 6F] 4A and 4B are side and perspective views of a fuel tank mount; [Figure 7A] FIG. 2 is a perspective view of a rear suspension of the motorcycle. [Figure 7B] FIG. 1 is a perspective view of a rear suspension of a motorcycle removed from the vehicle body for clarity. [Figure 7C] FIG. 2 is a perspective view of the front end of the suspension. [Figure 7D] FIG. 13 is an enlarged perspective view of an extension for holding a knurled fastener for coupling to a shock absorber. [Figure 8A] FIG. 1 is a perspective view of a brake system of a motorcycle. [Figure 8B] FIG. 2 is an enlarged view of the head casting coupled to the brake manifold. [Figure 8C] FIG. 2 is a perspective view of a rear antilock brake sensor and a rear brake caliper. [Figure 8D] FIG. 2 is a side view of the anti-lock brake sensor housing. [Figure 9A] FIG. 2 is a perspective view of an electrical box mounted under a seat in a vehicle body. [Figure 9B] FIG. 2 is a perspective view of the electrical box and rear fender assembly. [Figure 9C] FIG. 1 is a partial exploded view of the rear fender module mount and electrical box cover. [Figure 10A] FIG. 2 is a perspective view of a rear fender assembly having a license plate mount; [Figure 10B] FIG. 1 is a rear view of the license plate mount coupled to the rear fender assembly. [Figure 10C] FIG. 2 is a partial cross-sectional view of the license plate holder and the left arm of the vehicle body. [Figure 10D] FIG. 15 is an exploded view of the left arm, the right arm, and the license plate holder shown in FIGS. 10A to 10C. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Corresponding reference numerals indicate corresponding parts in the several views of the drawings.

[0015] Exemplary embodiments will now be described in more detail with reference to the accompanying drawings. Although the following description includes application to motorcycles, it is understood that the features herein may be applied to any suitable vehicle, such as snowmobiles, all-terrain vehicles, utility vehicles, mopeds, and scooters. The embodiments disclosed below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described to enable others skilled in the art to utilize its teachings.

[0016] Relative terms used in this disclosure are with respect to the motorcycle 10 in a normal riding position. The body orientation in FIG. 1 has a longitudinal axis 12 that corresponds to the normal direction of travel. Right, left, front, rear, down, and up all refer to the relative position of the body in a normal upright position on the road surface.

[0017] Although the present example is illustrated with respect to a motorcycle, many of the teachings presented herein also apply to other open vehicle designs, such as scooters and utility vehicles.

[0018] 1A-1E, various motorcycle designs are shown. Motorcycle 10 is shown as a touring style motorcycle. However, the present examples are applicable to other types of vehicles, including but not limited to snowmobiles, scooters, utility vehicles, and off-road vehicles, as well as other types of motorcycles.

[0019] Motorcycle 10 includes a frame 14 that is used to support vehicle components including a front wheel 16 and a rear wheel 18. The front wheel 16 is coupled to a fork 20. The fork 20 rotates relative to the frame 14 to provide steering for the vehicle. The fork 20 is coupled to handlebars 22 that are used to rotate the fork 20 relative to the frame 14.

[0020] The rear wheels 18 are coupled to the frame 14 and a powertrain assembly 30. In this example, the powertrain assembly 30 is used to provide rotational power to the rear wheels 18. Of course, all or a selected number of the wheels of the vehicle may be coupled to the powertrain assembly 30. The powertrain assembly 30 includes an engine 32 and a transmission 34. The engine 32 has a front cylinder bank 36 and a rear cylinder bank 38. Both the front cylinder bank 36 and the rear cylinder bank 38 house cylinders and pistons (not shown). The combustion process occurs within the cylinders. The rotational power of the cylinders of a crankshaft (not shown) is provided to the transmission 34, which rotates, which in turn rotates a chain or belt to drive the rear wheels.

[0021] As best shown in FIG. 1C, the rear wheel 18 is coupled to the frame 14 via a rear suspension 44. A pivot mount 46 located on the frame 14 is used to couple the rear suspension 44 to the frame. A shock absorber 48 extends from a shock mount 50 located at a different position on the frame. The shock mount 50 is attached above and behind the pivot mount 46. The shock mount 50 couples one end of the shock absorber 48 to the frame 14. An extension mount 52 couples the other end of the shock absorber to the frame 14. The extension mount 52 is located on a swing arm 56. The swing arm 56 is attached to the pivot mount 46 and the rear wheel 18. As best shown in FIG. 1E, the shock absorber 48 is disposed at an angle θ with respect to the horizontal plane on which the vehicle travels, approximately the same as the upper twin portion 62 of the frame. The shock absorber may be within 10° or more preferably within 5° of the angle β of the upper twin portion 62 of the frame 14.

[0022] The engine 32 includes an airbox 40 for supplying air to the engine 32 during the combustion process.

[0023] The motorcycle 10 has a seat 70 having a first seating position 72 and a second seating position 74. The second seating position 74 includes a backrest 76. Various seat configurations may be used for different models of motorcycle 10; that is, only a front seat, a suspended front seat, or no second seating position 74 may be provided. The backrest 76 may also be eliminated. The first seating position 72 and the second seating position 74 may be attached to a frame as shown in FIG. 1E, and the rear seating position may be attached to a rear fender assembly 100 as best shown in FIG. 1E.

[0024] Saddlebags 78 (two of which are shown) are attached to the vehicle frame. The saddlebags 78 may be made from a variety of synthetic or natural materials. For example, cloth, vinyl, plastic, and leather may all be used for the saddlebag materials. Grab straps 80 may be positioned at the second seating position 74 so that the rear passenger has something to grab onto.

[0025] A fuel tank 82 is mounted to the frame 14. Mounting details of the fuel tank 82 are described in more detail below. Other features mounted to the frame 14 include several stylistic features such as highway bars 84, foot rests 86, passenger foot pegs 88, and driver foot pegs 90 shown in Figure IE. As shown in Figures 1A-1E, a variety of seating foot peg and other foot rest positions may be provided for various configurations of the motorcycle 10.

[0026] The front end of the vehicle body may include a windscreen 92 , headlights 94 , fog lights 96 , and turn signals 98 .

[0027] The front fork 20 may support a front fender 102. A fork cover 104 may be disposed over at least a portion of the front fork 20. The fork cover 104 is sometimes referred to as a "cowbell."

[0028] 2A-2E and 3A-3B, the frame 14 is formed from a number of frame members shown in further detail. The frame includes a backbone frame member 110. The backbone frame member 110 is a hollow tube disposed longitudinally of the motorcycle 10 defined by the longitudinal axis 12 described above. As described in further detail below, the backbone frame member 110 is hollow and may be used to route wires therethrough. The backbone frame member 110 is coupled to another frame member, such as a neck 112. The neck 112 may be welded or otherwise attached to the backbone frame member 110. The neck 112 is a stationary component and receives a steering assembly that rotates within the neck to turn the motorcycle 10 in a desired direction. The neck 112 is further connected to a pair of frame members referred to as front rails 114. The front rails 114 lead to another frame member, a bottom rail 116.

[0029] A pair of frame members, cross members 118, extend from the backbone frame member 110 to the front rail 114. Another frame member, upper twin section 62, extends from the backbone frame member 110 and connects to another frame member, lower rear rail 120, which joins with the lower rail 116. A pair of additional frame members, cross rails 122, extend from the intersection of the backbone frame member 110 and the upper twin section 62.

[0030] The various rails and frame members may be directly fastened or welded to one another or may be welded to one another via connectors. In particular, the cross member 118 is joined to the backbone frame member 110 by a first connector 124. The connector 124 also has a flange 126 having an opening 128. As described in more detail below, the opening 128 may receive electrical wires passing therethrough.

[0031] The cross member 118 may be joined to the front rail 114 by a head casting 130. The head casting 130 may also couple a front engine mount 132. The front engine mount 132 couples to the engine 32, and in particular to the engine block or housing.

[0032] The rear engine mount 134 is coupled to the cross rail 122. The engine mount 134 is also attached to the engine block or housing.

[0033] The rear connector 140 connects the backbone frame member 110, the cross rail 122, and the upper twin section 62. The rear connector 140 may be a cast member having an opening 142. Wires may extend from the opening 128 through the backbone frame member 110 and exit through the opening 142.

[0034] The cross rail 122 includes mounts 46. As described in more detail below, the mounts 46 are used to attach suspension components, such as a swing arm.

[0035] The engine 32 may also be attached by removing a removable portion 148 of the lower rail 116. The removable portion 148 may be coupled to the lower rail 116 via fasteners 150. A bracket 152 may be used to couple directly to the engine 32.

[0036] The lower fender 154 is part of the rear fender assembly 100. The lower fender 154 is attached to the intersection of the lower rear rail 120 and the upper twin section 62. That is, the lower fender 154 is mounted within the space between the upper twin section 62 and the lower rear rail 120. The fasteners 156 are used in conjunction with the shock mounts 50 described above with respect to the shock absorber 48.

[0037] 2E, there is shown in further detail the head casting 130 coupled to the front rail 114. The front rail 114 is coupled to the head casting 130 for supporting a front engine mount 132. In particular, the head casting 130 has a cross member 162 that receives fasteners 164 from the underside of the head casting 130. The fasteners 164 are generally inserted upward into the head casting 130.

[0038] The fasteners 166 connect directly to the engine or engine block. The fasteners 166 may include bushings and threaded fasteners. The cross member 162 of the head casting 130 may also include one or more brake manifold mounts 168. In this example, two brake manifold mounts 168 are described.

[0039] 3B, the rear engine mount 134 is shown in greater detail. Fasteners 136 on each side of the rear engine mount 134 are connected directly to the engine 32.

[0040] 4A-4P, the front end of motorcycle 10 is shown in further detail. However, the rear of motorcycle 10 is also shown with some components removed to show a portion of the rear in more detail. In this example, transmission 34 is coupled to the rear wheel via gear 190. Gear 190 is coupled to transmission 34 via belt 192. Of course, rear gear 190 and belt 192 may be replaced with sprockets and a chain.

[0041] As mentioned above, the front of the vehicle body has a fork 20. As mentioned above, the fork 20 has a fork cover 104 coupled thereto. The fork is held apart by a first triple clamp 200 and a second triple clamp 202. A neck 112 is disposed between the first triple clamp 200, the second triple clamp 202, and the fork 20. The handlebar 22 rotates on an axis 204 defined by the neck 112. The neck 112 has a steering stem 206, best shown in FIG. 4B. The fork 20 has a fixed portion 20A and an active portion 20B. The active portion 20B may be referred to as a hydraulic chamber.

[0042] The lower fork 20B has an axle 208 that extends between the hydraulic chambers. The axle 208 has the front wheel 16 secured thereto.

[0043] Component mount 210 is used to secure various components such as headlights, fog lights, and / or turn signals. In this example, component mount 210 has three openings for receiving fasteners to secure a headlight or other component to component mount 210.

[0044] Upper triple clamp 202 has a clock opening 212 that is angled relative to the longitudinal axis 12 of the vehicle, at an inward angle A relative to the longitudinal axis 12. During assembly, fasteners 214 are used to secure triple clamp 202 to fork 20. Similarly, fasteners 216 are used to secure lower triple clamp 200 to fork 20.

[0045] The handlebar receiver 218 is disposed within the upper triple clamp 202 .

[0046] 4C, there is shown a detailed front end view of motorcycle 10. In this example, headlight 94 is coupled to component mount 210 using fasteners 222. In this example, two fasteners 222 are shown. Turn signals 98 are mounted to the sides of fork 20.

[0047] A method of assembling a motorcycle front end is described. In FIG. 4D, a lower triple clamp 200 has a fork cover 104 coupled to the lower triple clamp 200 by fasteners 226. The lower triple clamp 200 is then inserted onto the fork 20 so that the fork 20 is received within the opening 228. The fork cover 104 and triple clamp assembly are shown in FIG. 4E. As shown in FIG. 4E, a steering stem 206 is coupled to the lower triple clamp 200. A fork tube grommet 230 has a cylindrical portion 232 and a flange 234. The cylindrical portion 232 is disposed around the fork 20. The steering stem 206 is also coupled to the lower triple clamp 200. After the grommet 230 is coupled to the fork 20, the upper triple clamp 202 is placed onto the fork 20 so that it rests on the flange 234 of the grommet 230. The fasteners 214 secure the upper triple clamp to the fork 20. Fasteners 216 secure lower triple clamp 200 to fork 20 .

[0048] 4G and 4H, a fork tube clamp 240 is shown. The tube clamp 240 is shown in several motorcycle configurations. The fork tube clamp 240 has a central portion 242 that wraps around the fork 20 between the lower triple clamp 200 and the upper triple clamp 202. As described in more detail below, the fork tube clamp 240 may be used to secure a front nacelle, windscreen, turn signals, or fog lights, or other components. In this example, two fork tube clamps 240 are shown. The fork tube clamp 240 has a central portion 242 that is directly or at least partially around the top of the fork tube 20. The fork tube clamp 240 has a fastening arm 244 that receives a fastener 246 for fastening the fork tube clamp 240 to the upper triple clamp 202. In this example, the fastener 246 is attached along an axis parallel to the fork 20.

[0049] The fork tube clamp 240 includes a slot 248. The slot 248 may be used to receive fasteners of various components coupled to the slot 248. As best shown in FIGS. 4I and 4J, the clamp 240 may include two portions 240A and 240B secured together by a fastener 252. In FIG. 4I, the right-most fork tube clamp 240 is shown, which is on the left side of the figure when viewed from the front, similar to FIG. 4J. The slot 248 also couples the first portion 240A to the second portion 240B. The front portion of the front nacelle 260 is shown. The front nacelle 260 is mounted to the front of the motorcycle 10. In some configurations, the turn signal 98 may be attached to a bolt 262 that passes through the side of the front nacelle 260. The bolt 262 is mounted to the inside of the front nacelle 260. This is shown in FIG. 4K. The front nacelle 260 also includes a grommet 264. A grommet 264 extends upward from the front nacelle 260 and is inserted into an opening in the upper triple clamp 202. As shown in FIG. 4L, the front nacelle 260 with the turn signals 98 coupled thereto is placed on the fork 20 and slid in an upward motion as indicated by arrow 266. This allows the grommet 264 to seat in an opening in the bottom of the upper triple clamp 202. The front nacelle 260 may be coupled to the lower triple clamp 200 by fasteners 268. The fasteners 268 are received in component mounts 210, which are located rearward of the front nacelle 260 in FIG. 4L.

[0050] 4M, the front nacelle 260 is positioned such that the flange 234 of the grommet 230 separates the top of the front nacelle 260 from the upper triple clamp 202.

[0051] Referring to Figure 4N, the rear nacelles 270A, 270B are attached. As best seen in Figure 4J, two fasteners 272 are received in openings 274. Side fasteners 276 connect the front nacelle 260 to the rear nacelles 270A, 270B. In this example, three fasteners 276 are used. The headlight assembly may then be attached to the component mount 210 by fasteners adjacent to fasteners 268.

[0052] 4O, the opening 278 is aligned with the component mount 210 for mounting a headlight bucket 282 to the component mount 210. The access 280 formed by the fastener allows the headlight bucket 282 to rotate about the access 280. Thus, the headlight 94 can then be mounted within the headlight bucket 282.

[0053] 4P, the component mount 210 is shown in another embodiment. In some motorcycle configurations, the use of fog lights 96 is desirable. The fog lights 96 may be attached to an arm 284. The arm 284 is secured by a fastener 286. The headlight 94 may be secured to the mount 288.

[0054] 5A and 5B, a system for mounting a windscreen 92 is shown. The windscreen 92 has a windscreen mounting bracket 290 secured to the windscreen 92 by fasteners 292. The windscreen mounting bracket 290 extends longitudinally. The mounting bracket 290 uses two longitudinally disposed fasteners 294 to mount the windscreen mounting bracket 290 to the slots 248 of the fork tube clamp 240. The windscreen includes two windscreen mounting brackets 290, and therefore four fasteners 294 are used to couple the windscreen to the fork tube clamp 240. It should be noted that in the example with the windscreen, no nacelle is used; i.e., neither the front nacelle 260 nor the rear nacelles 270A, 270B are used.

[0055] 6A and 6B, the fuel tank 82 is shown relative to the backbone frame member 110. The fuel tank 82 is molded to define a tunnel 300 therein. In this example, the tunnel 300 has an upper portion 302 and a pair of side lobes 304. The upper portion 302 rests on the backbone frame member 110. After assembly, the side lobes 304 are on either side of the backbone frame member 110. The tunnel 300 is a generally U-shaped channel that extends longitudinally within the fuel tank 82. As described below, no visible fasteners are used to secure the fuel tank 82 to the backbone frame member 110. With particular reference to FIG. 6A, the tunnel 300 hides the fasteners of the fuel tank 82. The tunnel 300 may also be used to hide fuel lines and other electrical wiring. FIG. 6A shows an opening 128 in the flange 126 of the connector 124. As discussed above, connectors 124 connect cross member 118 to backbone frame member 110. Flanges 126 preferably provide smooth edges at openings 128 to prevent damage to wiring or fuel lines. Openings 128 may be lined with plastic or soft material. To further maintain the wiring and / or fuel lines near the underside of backbone frame member 110, trays 310 are used. Trays 310 have tray straps 312 that extend around or partially around backbone frame member 110. Tray straps 312 secure tray diverters 314 adjacent openings 128. Tray diverters 314 allow wiring to rest therein. That is, tray diverters 314 are positioned at a desired distance to maintain wiring and / or fuel lines directly adjacent backbone frame member 110. Tray diverters 314 also extend adjacent cross member 118. Thus, the wiring and / or fuel lines are directly adjacent to the cross member 118. The wiring 316 is directed toward the front end of the vehicle body and communicates with components such as a user display. The wiring 316 extends into the opening 128 in the flange 126 and may run within the backbone frame member 110 toward the rear connector 140.The opening 142 in the rear connector 140 allows the wiring 316 to exit the backbone frame member 110, as described above. A fuel line 318 may also be maintained within the tunnel 300.

[0056] 6A-6F, the backbone frame member 110 includes posts 320 secured thereto. In this example, four posts 320 are used. The posts 320 are spaced apart longitudinally, two on the right side and two on the left side of the backbone frame member 110. In this example, the rearmost post is located on the backbone frame member 110 between the connector 124 and the connector 140. The front post 320 is located between the neck 112 and the cross member 118. However, in different motorcycle configurations, the posts may be in different locations on the frame. The post 320 may include an isolator 322 disposed about its periphery. The isolator 322 may be formed of a resilient material, such as rubber, that insulates the fuel tank from metal-to-metal contact. The tunnel 300 has a first interior wall 324 and a second interior wall 326 (which may be continuous interior walls) that are used to secure a stationary bracket therein. In this example, the inner wall 324 and the second inner wall 326 each have a rear stationary bracket 328 secured thereto. Since the components may be metal, the rear stationary bracket 328 may be welded to the fuel tank 82 at the first inner wall 324 and the second inner wall 326. The rear stationary bracket 328 may be C-shaped to receive the rear post 320 and isolator 322 therein. The rear stationary bracket 328 may have a “C” shaped opening that opens toward the front of the motorcycle 10.

[0057] The first and second inner walls 324, 326 may also include a front stationary bracket 330. The front stationary bracket 330 may be fixed or welded to each of the inner walls 324. The front stationary bracket 330 has a different shape than the rear stationary bracket 328. The front stationary bracket 330 has a first flange 332 with an opening 334. As described in more detail below, the opening 334 may be specially shaped. The front stationary bracket 330 may also include a second flange 336 and a central portion 338 disposed between the first flange 332 and the second flange 336. The central portion 338 is curved and partially surrounds the isolator 322 when assembled, as shown in FIG. 6F. In this example, the second flange 336 has a nut 340 fixed thereto. The nut 340 may be welded to the second flange 336.

[0058] The support bracket 342 is coupled to the forward stationary bracket 330 and extends partially around the post 320 and the isolator 322. When assembled as shown in FIG. 6F, the combination of the support bracket 342 and the forward stationary bracket 330 completely surrounds the isolator 322 of the post 320. During assembly of the fuel tank 82, the rear portion of the fuel tank is aligned with the post 320 and the isolator 322. The rear stationary bracket 328 is partially disposed around the isolator 322. That is, the isolator 322 and the post 320 are received within the rear stationary bracket 328 on either side of the backbone frame member 110. For convenience, the fuel tank 82 can be angled beyond the assembly angle to allow access for conveniently moving the fuel tank 82 to the appropriate position. Because the isolator 322 is rounded and the rear stationary bracket 328 is C-shaped, the fuel tank 82 can be partially rotated around the isolator 322 during the assembly process. The fuel tank is rotated to a counterclockwise position when viewed from the left side of the motorcycle 10 as shown in Figure 6A. The movement of the fuel tank 82 is such that the center portion 338 of the front stationary bracket 330 contacts the front isolator 322. The support bracket 342 is then attached to the front stationary bracket 330. This process is shown in Figures 6C-6D.

[0059] The support bracket 342 is elongated and has a first end 344 with a tab 346. The tab 346 includes a neck 348 that is connected to a central portion 350.

[0060] During a first assembly step, the tab 346 is inserted into the opening 334. The tab 346 is fully inserted into the opening 334 and the neck 348 engages the first flange 332. The auxiliary bracket 342 may be rotated within the opening 334 so that the neck 348 engages the first flange 332. The opening 334 may actually extend into a portion of the central portion 338. These steps are best shown in Figures 6C-6E. The auxiliary bracket 342 is then rotated and secured to the nut 340 by the fastener 352. The fastener 352 may be, for example, a dog point fastener. When fully assembled, the auxiliary bracket 342 and the tab 346 lie flush with the first flange 332 as shown in Figure 6F. The auxiliary bracket 342 is preferably flexible so that it bends and extends around the isolator 322. A second end 354 of the auxiliary bracket 342 has an opening 356. The opening 356 is used to receive the fastener 352. The fastener 352 is received within the nut 340. In this example, threads may be used to engage the nut 340.

[0061] In alternative configurations, different fasteners may be used other than nuts 340 and fasteners 352. Push pins, cable ties, etc. may be used. However, it is desirable to have fasteners that are removable in the event that maintenance is required on the fuel tank or other components of motorcycle 10. During fastening of fuel tank 82, both sides of fuel tank 82 are connected to isolators 322 and posts 320 in a similar manner.

[0062] As best shown in FIG. 6B, a magnet 358 may be incorporated into each side lobe 304 of the fuel tank 82. The magnet 358 may be secured to the fuel tank 82 directly adjacent to the forward stationary bracket 330, preferably below the stationary bracket 330, so that the auxiliary bracket 342 does not fall off during removal of the tank. That is, if the auxiliary bracket 342 is made of a magnetic material and the fuel tank 82 is made of a non-magnetic material, the magnet 358 may be placed inside the fuel tank 82 to hold the auxiliary bracket 342 during removal. The magnet 358 may be held in the fuel tank 82 by pockets, fasteners, or adhesives. Each side lobe 304 on either side of the backbone frame member 110 and adjacent to the tunnel 300 may have a magnet 358. For the same reason, the magnet 358 may also assist during assembly.

[0063] 7A-7D, the rear suspension 44 is shown in further detail. As discussed above, the swingarm 56 is pivotally coupled at the pivot mount 46 using fasteners 144. The swingarm 56 extends rearwardly from the cross rail 122. The swingarm 56 couples a rear wheel to the swingarm 56 using a rear axle 400. The rear axle 400 is secured to each side of the swingarm 56 by a fastening device 402. The shock absorber 48 is attached to the shock mount 50 using fasteners 156. A second end of the shock absorber 58 is coupled to the extension mount 52 by a knurled stud fastener 406. Details of the knurled stud fastener 406 are provided below. The knurled stud fastener 406 has a nut 408 that is used to secure the end of the shock absorber 58 to the extension mount 52.

[0064] As best shown in FIG. 7B, the swing arm 56 includes a cross member 410 that extends from the first arm 56A to the second arm 56B of the swing arm 56.

[0065] As best seen in FIG. 7C, a nut 414 is coupled to the fastener 144 to secure the fastener 144 to the cross rail 122 .

[0066] 7D, the knurled stud fastener 406 is shown in further detail. The knurled stud fastener 406 has a knurled portion 420, a threaded portion 422, and a smooth portion 424. The smooth portion 424 is disposed between the knurled portion 420 and the threaded portion 422. The knurled stud fastener also has a head 426 that is coupled to the extension mount 52. The head 426 may be partially or completely recessed within the extension mount 52.

[0067] 8A-8C, a brake system for the motorcycle 10 will now be described. In this example, a master cylinder 440 in fluid communication with a brake manifold 442. The brake manifold 442 is coupled to the head casting 130, and in particular to the brake manifold mount 168, shown in FIG. 2E. Fasteners 444 couple the master cylinder 440 to the brake manifold mount 168. The master cylinder 440 is coupled to the brake manifold 442 via a brake line 446. A brake line 448 is coupled to the hand brake and to the top of the manifold 442. The bottom of the brake manifold 442 may be coupled to a front brake caliper 450 via a brake line 449 in a non-ABS system, or to an ABS controller 466 in an ABS system. The front brake caliper 450 is directly adjacent to a front brake disc 452. A front anti-lock brake sensor 454 is located on the other side of the front brake disc 452. The handlebar 22 may be modified to customize the motorcycle 10. Typically, replacing brake lines is a task that takes several hours. By providing the brake manifold 442 in this location, only a short section of the brake lines 448 needs to be replaced when replacing the handlebar 22. Thus, the time required for customization is reduced.

[0068] The rear portion of the motorcycle 10 includes a rear brake caliper 460 and a rear anti-lock brake sensor assembly 462. A rear disc 464 is disposed adjacent to the rear brake caliper 460.

[0069] The anti-lock braking system of the motorcycle 10 includes an anti-lock braking system controller 466. The controller 466 controls the operation of the rear brake caliper 460 and the front caliper 450.

[0070] The rear ABS sensor assembly 462 is best seen in Figure 8D. The rear ABS sensor has two sets of communication wires 466A and 466B.

[0071] 8D, the details of the rear ABS sensor assembly 462 will be described in further detail. The rear ABS sensor assembly 462 has a circular shaped housing 468 and is located in the center of the rear wheel / rear brake disc 464. The housing holds two ABS sensors 470 and 472. The ABS sensors 470 and 472 may have different configurations, and thus one may have two wires for communication, one may have a tree wire for communication, or both may be the same. Although the rear wheel 18 is shown with respect to the ABS sensor housing 468, the front wheel 16 may also have a housing 468.

[0072] 9A, the rear portion of the vehicle body is shown in greater detail. In this example, the seats have been removed and an electrical box 500 has been coupled between the cross rail 122 and the lower rear rail 120. The electrical box 500 may be formed of a composite material such as plastic. The electrical box 500 is attached by fasteners 502 to brackets 504 extending from each frame member.

[0073] 9B, the electrical box 500 houses a battery 510 and an engine control module 512. A bracket strap 514 is used to secure the battery 510 within the electrical box 500.

[0074] A fuse box 520 is also located beneath the seat. The fuse box 520 may be a weather sealed component and extends between the upper twin sections 62.

[0075] An evaporation canister 522 is also coupled to the upper twin section 62. The evaporation canister 522 may be an optional element and is provided where required by law.

[0076] The electrical box 500 includes a cover 530. The cover 530 includes tabs 532 that engage at least one wall of the electrical box 500.

[0077] A starter 534 is located adjacent to the electrical box 500 beneath the seating area.

[0078] The cover 530 may also house antennas thereon. A tire pressure monitoring system antenna 536 and a key fob antenna 538 may be integrated onto the cover 530.

[0079] 9A and 9B, the lower fender 154 is shown. The lower fender 154 has a module mount 550 coupled thereto. The module mount 550 is used to secure a cellular modem 552 and a body control module 554. A tab 556 extending from the module mount 550 is used to secure the cellular modem in the body control module 554 to the module mount. The tab 556 may be integrally molded with the module mount 550. Alternatively, other types of fasteners may be used in addition to the tab 556. For example, straps and various types of fasteners may be used to attach the module to the module mount 550.

[0080] 10A-10D, the rear fender assembly 100 has been briefly described above. The rear fender assembly 100 includes a module mount 550, a cellular modem 552, a body control module 554, a lower fender 154, and an upper fender 570. The upper fender 570 is coupled to the lower fender 154 and has a volume between the upper fender 570 and the lower fender 154, in which the cellular modem 552, the body control module 554, and a connector coupled to the body control module 554 are disposed. The upper fender 570 may have an upper reflector 572 coupled thereto. A tail light 574 may also be coupled to the rear fender assembly 100, and more specifically, to either the lower fender 154 or the upper fender 570, or both. The tail light 574 may function as a rear marker light and a turn signal. The tail lights 574 may each be attached to a respective arm 576, 578. A right arm 578 is coupled to the upper fender and has a wire 580 routed therein. A left tail light 574 is attached to a left arm 576, which also has a wire 582 disposed therein. A support 584 may extend between the tail light 574 and the arms 576, 578. The left arm 576 may be configured differently than the right arm 578. In this example, a license plate holder 586 is rotatably coupled to the left arm 576. The pivoting license plate holder 586 may fold if it contacts the ground or other obstruction. The license plate holder 586 has one or more recesses 588. In this example, the recesses 588 receive a GPS antenna 590. The license plate holder 586 has an extension 592 extending upward from a top of the license plate holder 586. The extension 592 may house a license plate lamp 594. License plate lamp 594 shines light onto the surface of a license plate (not shown) when properly attached to the surface of license plate holder 586. Wires for license plate lamp 594 and GPS antenna 590 extend into left arm 576.

[0081] The license plate holder 586 may also house one or more electronic communication components 591 used to communicate with devices external to the motorcycle. The electronic communication components 591 may include an RFID tag, an NFC communication device, a global positioning system, a vehicle-to-vehicle communication device, an IoT communication device, an AM or FM receiver or antenna, etc. The electronic communication component 591 may be an electronic toll collection transponder.

[0082] 10D, the license plate holder 586 and the left arm 576 are shown in more detail. The left arm 576 may further include a retainer 596 for retaining any wires. Similarly, a retainer 598 retains the wires in the right arm 578. The license plate holder 586 may have a spring 600 disposed therein to prevent rotation of the license plate holder 586 about a pivot 602. The pivot 602 may be formed integrally with the left arm 576 or may be formed as a separate component. The pivot 602 forms an axis about which the license plate holder 586 can rotate. If the motorcycle 10 falls over, the license plate holder 586 can pivot out of the way. FIG. 10D also shows a recess 589 used for the wires and the license plate lamp 594.

[0083] A retainer 604 and washer 605 hold the spring 600 in a channel 606 that also receives the pivot 602. A portion 608 at the end of the recess 589 receives the GPS antenna wires and license plate wires, routing the wires to the pivot 602 and then through the left arm 576.

[0084] Fasteners 610 are used to join left arm 576 and right arm 578 to the fender assembly. Fasteners 612 join retainers 596 and 598 to left arm 576 and right arm 578, respectively. Nuts 614 join license plate lamp 594 to license plate holder 586.

[0085] The description of the foregoing examples has been provided for purposes of illustration and description. The description of the foregoing examples is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular example are generally not limited to that particular example and, where applicable, may be interchangeable and used in selected embodiments even if not specifically shown or described. This may also be varied in various ways. Such variations should not be considered as departures from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. a first frame member having a first opening; A plurality of wires; a joint member coupled to the first frame member and at least a second frame member, the joint member including a second opening therein; and Including, the plurality of wires extend through the first frame member and the second opening of the joint member to the first opening; Motorcycle.

2. The motorcycle according to claim 1 , wherein the first opening is in a lower surface of the first frame member.

3. The motorcycle of claim 1 , wherein the first opening is adjacent to a fuel tank in a fuel tank tunnel.

4. 4. The motorcycle of claim 3, wherein the fuel tank has a first portion on a first side of the first frame member, a second portion on a second side of the first frame member, and a third portion on the first frame member, the first portion, the second portion, and the third portion defining the fuel tank tunnel, and further including a wire guide positioned below the first frame member and within the tunnel to guide the plurality of wires out of the first opening.

5. 4. The motorcycle of claim 3, wherein the fuel tank is coupled to the first frame member at a first stationary bracket coupled to the fuel tank, a second stationary bracket coupled to the fuel tank, a third stationary bracket coupled to the fuel tank, and a fourth stationary bracket coupled to the fuel tank.

6. 6. The motorcycle of claim 5, wherein the third and fourth stationary brackets are C-shaped and pivotally mounted to third and fourth posts extending from the first frame member.

7. 7. The motorcycle of claim 6, further comprising a first auxiliary bracket coupled to the first stationary bracket, the first auxiliary bracket and the first stationary bracket being disposed about a first post extending from the first frame member, and a second auxiliary bracket coupled to the second stationary bracket such that the second auxiliary bracket and the second stationary bracket are disposed about a second post.

8. 8. The motorcycle of claim 7, wherein a first end of the first auxiliary bracket includes a tab inserted into an opening in the first end of the first stationary bracket, and a second end of the auxiliary bracket is coupled to the second end of the first stationary bracket by a fastener.

9. 9. The motorcycle of claim 8, wherein the fastener is a removable fastener and further includes a first magnet disposed within the fuel tank adjacent the first auxiliary bracket and a second magnet disposed within the fuel tank adjacent the second auxiliary bracket.

10. a first frame member and a second frame member, the first frame member being spaced apart from the second frame member; a first hand brake disposed on the handlebar; a brake manifold coupled to the first frame member and coupled to a first brake line extending from the first frame member, the first brake line being separable from the brake manifold; Including motorcycles.

11. The motorcycle according to claim 10, wherein the brake manifold is disposed in front of a fuel tank.

12. 11. The motorcycle of claim 10, further comprising a bracket coupled between the first frame member and the second frame member, the brake manifold being coupled to the bracket.

13. 13. The motorcycle of claim 12, further comprising an engine, the bracket including an engine mount coupled to the bracket, the engine mount coupled to the engine.

14. 11. The motorcycle of claim 10, further comprising a second brake line coupled between the brake manifold and a master cylinder.

15. 15. The motorcycle of claim 14, further comprising a third brake line coupled between an anti-lock brake (ABS) module and the brake manifold.

16. 16. The motorcycle of claim 15, further comprising an ABS sensor coupled to the ABS module.

17. 17. The motorcycle of claim 16, wherein the ABS sensor includes five wires in communication with the ABS module.

18. A first fork; a second fork spaced from the first fork; a first triple clamp coupled between the first fork and the second fork; a second triple clamp coupled between the first fork and the second fork; a first grommet disposed on the first fork adjacent the second triple clamp, the first grommet having a first spacer flange extending therefrom; a second grommet disposed on the second fork adjacent the second triple clamp, the second grommet having a second spacer flange extending therefrom; Including motorcycles.

19. 19. The motorcycle of claim 18, further comprising: a first fork cover coupled about the first fork and coupled to the first triple clamp; and a second fork cover coupled about the second fork and coupled to the first triple clamp.

20. 19. The motorcycle of claim 18, further including a first fork tube clamp coupled around the first fork between the first triple clamp and the second triple clamp, the first fork tube clamp coupled to the second triple clamp by a first fastener, and further including a second fork tube clamp coupled around the second fork between the first triple clamp and the second triple clamp, the second fork tube clamp coupled to the second triple clamp by a second fastener.

21. 21. The motorcycle of claim 20, wherein the first fastener and the second fastener are coupled to a lower surface of the second triple clamp.

22. 21. The motorcycle of claim 20, further comprising a front nacelle coupled to the first and second forks by the first and second fork tube clamps, respectively.

23. 23. The motorcycle according to claim 22, wherein the first spacer flange and the second spacer flange are disposed between the front nacelle and the second triple clamp.

24. 24. The motorcycle of claim 23, wherein a first grommet includes the first spacer flange and a second grommet includes the second spacer flange.

25. 21. The motorcycle of claim 20, further comprising a first turn indicator and a second turn indicator coupled to the front nacelle.

26. 21. The motorcycle of claim 20, further comprising a first windscreen mount coupled to the first fork tube clamp and a second windscreen mount coupled to the second fork tube clamp, and further comprising a windscreen coupled to the first windscreen mount and the second windscreen mount.

27. 20. The motorcycle of claim 18, further comprising a headlight coupled to the first triple clamp.

28. 20. The motorcycle of claim 18, further comprising a fog light coupled to the first triple clamp.

29. a first cross rail and a second cross rail spaced apart from the second cross rail; an elongated swing arm including a first arm and a second arm, the swing arm having a first end and a second end, the first end including a first cross member and a second cross member, the first cross member being hollow and sized to receive fasteners rotatably joining the swing arm to the first cross rail and the second cross rail; a first shock absorber coupled to a second end of the first arm and a second shock absorber coupled to the second end of the second arm; Including motorcycles.

30. 30. The motorcycle of claim 29, wherein the second end is coupled to a rear wheel.

31. 30. The motorcycle of claim 29, further including a center frame member and a pair of upper frame members extending rearwardly from the upper frame member at approximately a first line at a first angle from a horizontal line, wherein when the motorcycle is stopped, the first shock absorber forms a second angle approximately the same as the first angle.

32. 32. The motorcycle of claim 31, wherein the second angle is 10 degrees from the first angle.

33. 32. The motorcycle of claim 31, wherein the second angle is within 5 degrees of the first angle.

34. 30. The motorcycle of claim 29, wherein the first shock absorber has the second end coupled to the first arm proximate a second end thereof, and the second shock absorber has the second end coupled to the second arm proximate a second end thereof.

35. 30. The motorcycle of claim 29, wherein the first arm includes a first extension coupled to the second end of the first shock absorber, and the second arm includes a second extension coupled to the second end of the second shock absorber.

36. 36. The motorcycle of claim 35, wherein the first extension is coupled to the second end of the first shock absorber by a first knurled stud and the second extension is coupled to the second end of the second shock absorber by a second knurled stud.

37. 37. The motorcycle of claim 36, wherein the first knurled stud has a head disposed inwardly of the elongated swingarm and a threaded portion extending from the first extension.

38. a lower frame member including a tube cradle, a plurality of wires disposed within the tube cradle, the tube cradle including a side opening; a holding cradle coupled to the side opening; a retaining cover connecting the retaining cradle to the side opening; Including motorcycles.

Images