EP4665633A1 - Frame for an all-terrain vehicle and all-terrain vehicle comprising the same - Google Patents

Frame for an all-terrain vehicle and all-terrain vehicle comprising the same

Info

Publication number
EP4665633A1
EP4665633A1 EP24756450.3A EP24756450A EP4665633A1 EP 4665633 A1 EP4665633 A1 EP 4665633A1 EP 24756450 A EP24756450 A EP 24756450A EP 4665633 A1 EP4665633 A1 EP 4665633A1
Authority
EP
European Patent Office
Prior art keywords
terrain vehicle
frame
airbox
extending
members
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24756450.3A
Other languages
German (de)
French (fr)
Inventor
Pascal Jacques
Simon FILLION
Sacha BOUCHARD
Gabriel GOSSELIN
Christian De Grammont
Jeremie DUFORD
Remi Breton
Eric Bertrand
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bombardier Recreational Products Inc
Original Assignee
Bombardier Recreational Products Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bombardier Recreational Products Inc filed Critical Bombardier Recreational Products Inc
Publication of EP4665633A1 publication Critical patent/EP4665633A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D23/00—Combined superstructure and frame, i.e. monocoque constructions
    • B62D23/005—Combined superstructure and frame, i.e. monocoque constructions with integrated chassis in the whole shell, e.g. meshwork, tubes, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B35/00—Axle units; Parts thereof ; Arrangements for lubrication of axles
    • B60B35/12—Torque-transmitting axles
    • B60B35/14—Torque-transmitting axles composite or split, e.g. half- axles; Couplings between axle parts or sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G3/00—Resilient suspensions for a single wheel
    • B60G3/18—Resilient suspensions for a single wheel with two or more pivoted arms, e.g. parallelogram
    • B60G3/20—Resilient suspensions for a single wheel with two or more pivoted arms, e.g. parallelogram all arms being rigid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G9/00—Resilient suspensions of a rigid axle or axle housing for two or more wheels
    • B60G9/003—Resilient suspensions of a rigid axle or axle housing for two or more wheels the axle being rigidly connected to a trailing guiding device
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K11/00—Arrangement in connection with cooling of propulsion units
    • B60K11/02—Arrangement in connection with cooling of propulsion units with liquid cooling
    • B60K11/04—Arrangement or mounting of radiators, radiator shutters, or radiator blinds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K13/00—Arrangement in connection with combustion air intake or gas exhaust of propulsion units
    • B60K13/02—Arrangement in connection with combustion air intake or gas exhaust of propulsion units concerning intake
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D21/00—Understructures, i.e. chassis frame on which a vehicle body may be mounted
    • B62D21/18—Understructures, i.e. chassis frame on which a vehicle body may be mounted characterised by the vehicle type and not provided for in groups B62D21/02 - B62D21/17
    • B62D21/183—Understructures, i.e. chassis frame on which a vehicle body may be mounted characterised by the vehicle type and not provided for in groups B62D21/02 - B62D21/17 specially adapted for sports vehicles, e.g. race, dune buggies, go-karts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62J—CYCLE SADDLES OR SEATS; AUXILIARY DEVICES OR ACCESSORIES SPECIALLY ADAPTED TO CYCLES AND NOT OTHERWISE PROVIDED FOR, e.g. ARTICLE CARRIERS OR CYCLE PROTECTORS
    • B62J11/00—Supporting arrangements specially adapted for fastening specific devices to cycles, e.g. supports for attaching maps
    • B62J11/10—Supporting arrangements specially adapted for fastening specific devices to cycles, e.g. supports for attaching maps for mechanical cables, hoses, pipes or electric wires, e.g. cable guides
    • B62J11/19—Supporting arrangements specially adapted for fastening specific devices to cycles, e.g. supports for attaching maps for mechanical cables, hoses, pipes or electric wires, e.g. cable guides specially adapted for electric wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62J—CYCLE SADDLES OR SEATS; AUXILIARY DEVICES OR ACCESSORIES SPECIALLY ADAPTED TO CYCLES AND NOT OTHERWISE PROVIDED FOR, e.g. ARTICLE CARRIERS OR CYCLE PROTECTORS
    • B62J11/00—Supporting arrangements specially adapted for fastening specific devices to cycles, e.g. supports for attaching maps
    • B62J11/22—Supporting arrangements specially adapted for fastening specific devices to cycles, e.g. supports for attaching maps specially adapted for tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62J—CYCLE SADDLES OR SEATS; AUXILIARY DEVICES OR ACCESSORIES SPECIALLY ADAPTED TO CYCLES AND NOT OTHERWISE PROVIDED FOR, e.g. ARTICLE CARRIERS OR CYCLE PROTECTORS
    • B62J17/00—Weather guards for riders; Fairings or stream-lining parts not otherwise provided for
    • B62J17/02—Weather guards for riders; Fairings or stream-lining parts not otherwise provided for shielding only the rider's front
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62J—CYCLE SADDLES OR SEATS; AUXILIARY DEVICES OR ACCESSORIES SPECIALLY ADAPTED TO CYCLES AND NOT OTHERWISE PROVIDED FOR, e.g. ARTICLE CARRIERS OR CYCLE PROTECTORS
    • B62J17/00—Weather guards for riders; Fairings or stream-lining parts not otherwise provided for
    • B62J17/10—Ventilation or air guiding devices forming part of fairings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62J—CYCLE SADDLES OR SEATS; AUXILIARY DEVICES OR ACCESSORIES SPECIALLY ADAPTED TO CYCLES AND NOT OTHERWISE PROVIDED FOR, e.g. ARTICLE CARRIERS OR CYCLE PROTECTORS
    • B62J40/00—Arrangements of air cleaners specially adapted for cycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62J—CYCLE SADDLES OR SEATS; AUXILIARY DEVICES OR ACCESSORIES SPECIALLY ADAPTED TO CYCLES AND NOT OTHERWISE PROVIDED FOR, e.g. ARTICLE CARRIERS OR CYCLE PROTECTORS
    • B62J41/00—Arrangements of radiators, coolant hoses or pipes on cycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDECARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/30—Frame parts shaped to receive other cycle parts or accessories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDECARS, FORECARS, OR THE LIKE
    • B62K27/00—Sidecars; Forecars; Trailers or the like specially adapted to be attached to cycles
    • B62K27/10—Other component parts or accessories
    • B62K27/12—Coupling parts for attaching cars or the like to cycle; Arrangements thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDECARS, FORECARS, OR THE LIKE
    • B62K5/00—Cycles with handlebars, equipped with three or more main road wheels
    • B62K5/01—Motorcycles with four or more wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDECARS, FORECARS, OR THE LIKE
    • B62K5/00—Cycles with handlebars, equipped with three or more main road wheels
    • B62K5/08—Cycles with handlebars, equipped with three or more main road wheels with steering devices acting on two or more wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2200/00—Indexing codes relating to suspension types
    • B60G2200/10—Independent suspensions
    • B60G2200/14—Independent suspensions with lateral arms
    • B60G2200/144—Independent suspensions with lateral arms with two lateral arms forming a parallelogram
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2200/00—Indexing codes relating to suspension types
    • B60G2200/20—Semi-rigid axle suspensions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2200/00—Indexing codes relating to suspension types
    • B60G2200/30—Rigid axle suspensions
    • B60G2200/31—Rigid axle suspensions with two trailing arms rigidly connected to the axle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2200/00—Indexing codes relating to suspension types
    • B60G2200/40—Indexing codes relating to the wheels in the suspensions
    • B60G2200/422—Driving wheels or live axles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2200/00—Indexing codes relating to suspension types
    • B60G2200/40—Indexing codes relating to the wheels in the suspensions
    • B60G2200/44—Indexing codes relating to the wheels in the suspensions steerable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2204/00—Indexing codes related to suspensions per se or to auxiliary parts
    • B60G2204/10—Mounting of suspension elements
    • B60G2204/12—Mounting of springs or dampers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2204/00—Indexing codes related to suspensions per se or to auxiliary parts
    • B60G2204/10—Mounting of suspension elements
    • B60G2204/19—Mounting of transmission differential
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2204/00—Indexing codes related to suspensions per se or to auxiliary parts
    • B60G2204/40—Auxiliary suspension parts; Adjustment of suspensions
    • B60G2204/43—Fittings, brackets or knuckles
    • B60G2204/4302—Fittings, brackets or knuckles for fixing suspension arm on the vehicle body or chassis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/30—Constructional features of rigid axles
    • B60G2206/31—Straight axle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/70—Materials used in suspensions
    • B60G2206/72—Steel
    • B60G2206/722—Plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/80—Manufacturing procedures
    • B60G2206/82—Joining
    • B60G2206/8201—Joining by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2300/00—Indexing codes relating to the type of vehicle
    • B60G2300/07—Off-road vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2300/00—Indexing codes relating to the type of vehicle
    • B60G2300/12—Cycles; Motorcycles
    • B60G2300/124—Quads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2200/00—Type of vehicle
    • B60Y2200/10—Road Vehicles
    • B60Y2200/12—Motorcycles, Trikes; Quads; Scooters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2200/00—Type of vehicle
    • B60Y2200/10—Road Vehicles
    • B60Y2200/12—Motorcycles, Trikes; Quads; Scooters
    • B60Y2200/124—Buggies, Quads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDECARS, FORECARS, OR THE LIKE
    • B62K5/00—Cycles with handlebars, equipped with three or more main road wheels
    • B62K2005/001—Suspension details for cycles with three or more main road wheels

Definitions

  • the invention relates to a frame for an all-terrain vehicle (ATV) and to an ATV comprising the same. More particularly, the frame for the ATV is adapted for housing engines having different sizes, and various configurations of rear suspensions.
  • the ATV is provided with a service center providing access to an airbox allowing service and maintenance of an air filter via the service center, and to a radiator configuration.
  • the invention further relates to steering assembly, gas tank and airbox configurations for an ATV, a hitch assembly and to a method for packaging such an all- terrain vehicle.
  • All-terrain vehicles are designed to operate in rough, off-road terrains and generally comprise a robust frame mounted on four wheels. Front and rear suspensions are provided between the frame and the wheel for absorbing bumps.
  • An engine is mounted to the frame and is operatively connected to the rear wheels, and in some instances, to the front wheels as well.
  • the front wheels are operatively connected to a steering assembly for steering the ATV, and a straddle seat is mounted to the frame for the operator to sit.
  • the straddle seat is positioned above the engine such that the rider is located proximal to the longitudinal position of the center of gravity of the ATV, to minimize the impact of the bumps encountered during the operation of the ATV.
  • ATVs are subject to relatively high bending and torsional forces, which have to be resisted by their frames.
  • Typical ATV frames sometimes referred to as “space” or “open structure” frames, have been constructed with sufficient strength and rigidity for ATV applications.
  • these frames are generally highly complex or use a significant amount of material.
  • Such typical frame configurations tend to be costly to manufacture and sometimes present the disadvantage of being heavy.
  • these frames generally need to be designed or redesigned according to the size of the engine that will be ultimately installed in the all-train vehicle.
  • ATVs are often used for pulling or hauling heavy equipment, camping gear, hunting gear, other farming or forestry equipment or even other all-terrain vehicles. Therefore, it is not uncommon for hitch receivers be installed on all-terrain vehicles. Such installations usually require drilling holes on the frame of the ATV, which may compromise the integrity of the frame.
  • hitch receivers When the frame of the all-terrain vehicles provide holes and weld nuts for installing a hitch receiver, it is not uncommon for such weld nuts and frame holes to be rusted or corroded from being exposed to the elements. In some cases, the edges of the frame holes may be so rusted that the original frame holes are not good for mounting the hitch receiver anymore.
  • ATVs are sometimes provided with a compartment or area trivially designated as “service center” in which are regrouped different vehicle components for easy access by a user, such as the fuse box, coolant fluid, power steering fluid and the like.
  • the service center can be provided on various locations on the ATV, including in the hood area, in front of the handlebar. While known ATV service centers provide easy access to some vehicle components, some other ATV elements that require regular maintenance are located outside the service center, for instance the airbox, and require dismantling other portions ofthe ATV such as cowlings and/orthe seat to provide a user with access to those elements for maintenance.
  • radiator While on many ATVs the radiator is typically located in front of the front wheels, under a cover that substantially shields the radiator from the elements, the operation of such ATVs in water or in muddy conditions leads to mud and debris to be splashed onto the radiator and cause it to block the air passing through the radiator to cool the engine coolant. In some instances, it was thus envisioned to move the radiator from a more conventional position to a raised position, where the radiator is positioned generally above the front wheel of the ATV, proximate to the handlebar. To protect the radiator, a radiator cover is provided. While this positioning of the radiator contributes to reduce the exposure of the radiator to debris and mud, they are nevertheless prone to clogging, and the maintenance or cleaning of the radiator sometimes requires tools and/or removal of cowlings.
  • a frame for an all-terrain vehicle comprising a main frame extending along a longitudinal axis and comprising a front portion, a middle portion and a rear portion, the front portion being configured to receive a portion of a front suspension, the rear portion being configured to receive a portion of a rear suspension, and the middle portion comprising: a left bottom longitudinal member extending from a left bottom proximal end portion through a middle portion to a left bottom distal end portion; a right bottom longitudinal member extending from a right bottom proximal end portion through a middle portion to a right bottom distal end portion; a left top longitudinal member extending from a left top proximal end portion through a middle portion to a left top distal end portion; and a right top longitudinal member extending from a right top proximal end portion through a middle portion to a right top distal end portion; a first distance being defined between one of the left top longitudinal member and
  • the space is defined between the one of the left and right top longitudinal members being at the first distance and the other of the left and right top longitudinal members being at the second distance.
  • the first distance is defined between the right top longitudinal member and the right bottom longitudinal member and the second distance is defined between the left top longitudinal member and the left bottom longitudinal member.
  • the space is defined between the left and right top longitudinal members. In one feature, the space is adapted to receive at least one component of the all-terrain vehicle. In one feature, the at least one component is selected from a group comprising a steering assembly, steering cables, an airbox, an air filter, a storage compartment and a battery.
  • the middle portion comprises: a front top cross-member extending between the left top distal end portion of the left top longitudinal member and the right top distal end portion of the right top longitudinal member, the front top cross-member comprising left and right end portions, and a left longitudinal member extending outwardly sidewardly from the left end portion of the front top cross-member or from the left top distal end portion of the left top longitudinal member and downwardly to a left bottom end portion, the space being defined above the left top longitudinal member and therebetween the left longitudinal member and the right top longitudinal member.
  • the middle portion comprises a front left member extending upwardly from the left bottom longitudinal member up to the front top cross-member and a front right member extending upwardly from the right bottom longitudinal member up to the front top cross-member.
  • the middle portion comprises a right longitudinal member extending outwardly sidewardly from the right proximal end portion of the front top crossmember or from the right top proximal end portion of the right top longitudinal member and downwardly to a right bottom end.
  • the first distance is between about 65 cm and about 45 cm and the second distance is between about 60 cm and about 40 cm.
  • the middle portion comprises: a first lower cross-member connecting the left bottom longitudinal member and the right bottom longitudinal member at the left and right bottom proximal ends; and a second lower cross-member comprising left and right end portions, and extending between the left bottom longitudinal member and the right bottom longitudinal member at the middle portion of the left and right bottom longitudinal members, the left end portion of the second lower cross-member connecting the front left member extending upwardly and the left bottom longitudinal member, and the right end portion of the second lower cross-member connecting the front right member extending upwardly and the right bottom longitudinal member.
  • the front top cross-member is a first top cross-member and wherein the middle portion comprises a second top cross-member connecting the first left and right top longitudinal members at respective left and right middle portions of the first left and right top longitudinal members.
  • the space is defined above the second top cross-member.
  • the middle portion comprises a rear left member extending upwardly from the left bottom distal end portion of the left bottom longitudinal member to the left distal end portion of the left top longitudinal member and a rear right member extending upwardly from the right bottom distal end portion of the right bottom longitudinal member to the right distal end portion of the right top longitudinal member.
  • the engine compartment is adapted to receive a first engine having a first size or a second engine having a second size without modification of the left and right bottom longitudinal members and of the left and right top longitudinal members, the second size being larger than the first size.
  • the middle portion comprises a rear left engine mounting bracket, a front left engine mounting bracket, a rear right engine mounting bracket and a front right engine mounting bracket, the rear and front left engine mounting brackets and the rear and front right engine mounting brackets comprising rear and front left connectors and rear and front right connectors for mounting one of the first and second engines to the middle portion.
  • the front suspension comprises left and right front shock absorbers.
  • the rear suspension comprises left and right rear shock absorbers.
  • a frame for an all-terrain vehicle comprising a main frame comprising a front portion, a middle portion and a rear portion extending along a longitudinal axis between a rear proximal end and a rear distal end, the rear portion comprising: a left member adjacent the rear proximal end, the left member extending upwardly from a left bottom end portion to a left top end portion, and a right member adjacent the rear proximal end, the right member extending upwardly from a right bottom end portion to a right top end portion; a left transversal arm adjacent the rear proximal end, the left transversal arm extending transversely between a left proximal end portion and a left distal end portion, and a right transversal arm adjacent the rear proximal end, the
  • the proximal end portions of the left and right transversal arms are pivotably mounted rearwardly of the left and right bottom end portions of the left and right members.
  • the hitch receiver comprises a central projection extending rearwardly along the longitudinal axis from a distal end portion to a proximal end portion, and left and right protrusions extending transversely from the distal end portion of the central projection, the left and right protrusions of the hitch receiver being mounted to the left and right proximal end portions of the left and right transversal arms and to the left and right members.
  • the left and right protrusions comprise left and right bottom protrusions extending transversely from the distal end portion, and left and right top protrusions extending transversely from the distal end portion, the left and right bottom protrusions of the hitch receiver being mounted to the left and right proximal end portions of the left and right transversal arms, and the left and right top protrusions of the hitch receiver being mounted to the left and right members.
  • the hitch receiver comprises a left flange between the left bottom and top protrusions and a right flange between the right bottom and top protrusions. In one feature, the hitch receiver comprises a left bottom flange between the left bottom protrusion and the central projection and a right bottom flange between the right bottom protrusion and the central projection.
  • the central projection comprises exterior and inner walls and the inner wall defines a housing for receiving an elongated portion of a hitch.
  • the left and right members comprise left and right rear surfaces and the left and right proximal end portions of the left and right transversal arms are mounted to the left and right rear surfaces.
  • the left and right proximal end portions of the left and right transversal arms comprise left and right rear surfaces
  • the left and right bottom protrusions of the hitch receiver are mounted to the left and right rear surfaces of the left and right proximal end portions of the left and right transversal arms
  • the left and right top protrusions of the hitch receiver are mounted to the left and right rear surfaces of the left and right members.
  • the left and right proximal end portions of the left and right transversal arms comprise left and right proximal ends extending longitudinally along left and right bottom mounting axes between the left and right bottom protrusions of the hitch receiver and the left and right members, the left and right proximal ends comprising left and right inner walls extending along the left and right bottom mounting axes and defining left and right housings.
  • the left and right bottom protrusions comprise left and right bottom apertures at respective distal ends and the left and right top protrusions comprise left and right top apertures at respective distal ends, the left and right bottom apertures being around the left and right bottom mounting axes.
  • the left and right members comprise left and right top holes and left and right bottom holes, the left and right top holes being aligned with the left and right top apertures, and the left and right bottom holes being around the left and right bottom mounting axes.
  • the frame comprises left and right bottom fasteners mounted in the left and right bottom apertures, in the left and right housings and in the left and right bottom holes, and left and right top fasteners mounted in the left and right top apertures and in the left and right top holes for affixing the hitch receiver to the left and right members.
  • the frame comprises left and right bushings mounted in the left and right housings and around the left and right bottom fasteners and the left and right proximal ends are pivotably mounted around the left and right bushings and left and right bottom fasteners for allowing pivotable movement of the left and right transversal arms relative to the left and right bottom mounting axes.
  • the left and right members comprise left and right bottom projections extending forwardly along the left and right bottom mounting axes, the left and right bottom projections comprising left and right inner walls defining left and right bottom channels aligned with the left and right bottom holes.
  • the left and right members comprise left and right top projections extending forwardly along left and right top mounting axes, the left and right top projections comprising left and right inner walls defining left and right top channels aligned with the left and right top holes.
  • the left and right bottom fasteners comprise left and right bottom bolts comprising left and right distal threaded ends and left and right bottom nuts
  • the left and right top fasteners comprise left and right top bolts comprising left and right distal threaded ends and left and right top nuts
  • the left and right distal threaded ends of the left and right bottom bolts extend forwardly outside the left and right bottom channels
  • the left and right distal threaded ends of the left and right top bolts extend forwardly outside the left and right top channels
  • the left and right bottom nuts are mounted to the left and right distal threaded ends of the left and right bottom bolts
  • the left and right top nuts are mounted to the left and right distal threaded ends of the left and right top bolts.
  • the frame comprises a left shock absorber adjacent the rear proximal end, the left shock absorber extending upwardly from a left bottom end portion to a left top end portion, and a right shock absorber adjacent the rear proximal end, the right shock absorber extending upwardly from a right bottom end portion to a right top end portion, the left and right bottom end portions of the left and right shock absorbers being mounted to the left and right transversal arms, and upon pivotal movement of the left and right transversal arms, the left and right shock absorbers are compressed or expanded.
  • the left and right transversal arms are left and right bottom transversal arms
  • the rear portion of the frame comprises left and right top transversal arms adjacent the rear proximal end
  • the left and right top transversal arms extend from left and right top proximal ends to left and right top distal ends
  • the left and right top proximal ends of the left and right top arms are pivotably mounted to the left and right members, and upon pivotal movement of the top and bottom left and right transversal arms, the left and right shock absorbers are compressed or expanded.
  • the left proximal end of the left transversal arm comprises a left rear external circular wall facing the left bottom protrusion of the hitch receiver
  • the right proximal end of the right transversal arm comprises a right rear external circular wall facing the right bottom protrusion of the hitch receiver
  • the left and right rear circular external walls and the left and right bottom protrusions define left and right rear spaces therebetween.
  • an all-terrain vehicle comprising a main frame comprising a front portion, a middle portion and a rear portion extending along a longitudinal axis between a rear proximal end and a rear distal end, the middle portion being configured to receive an engine
  • the front portion comprising: a left bottom longitudinal member extending from a front left bottom proximal end portion to a front left bottom distal end portion; a right bottom longitudinal member extending from a front right bottom proximal end portion to a front right bottom distal end portion; a first bottom cross-member extending between the left and right bottom longitudinal members and comprising: left and right ends; a proximal and distal surfaces; a first left transversal member adjacent to the left bottom distal end portion, the first left transversal comprising a proximal end and a distal end; and a first right transversal member adjacent to the right bottom distal end portion, the first right transversal member comprising
  • each of the first left and right transversal member comprises a front portion having a front distal end and a rear proximal end, and a rear portion having a rear distal end and a rear proximal end, the rear proximal ends of rear portions of the first left and right transverse members being connected to the bottom cross-member between the left and right longitudinal members.
  • the first left transversal member is pivotably mounted on a left axe provided at the proximal surface of first bottom cross-member
  • the first right transversal member is pivotably mounted on a right axe provided at the proximal surface of the first bottom cross-member.
  • the first left transversal member extends slightly upwardly and away from the bottom cross-member passing overthe front left bottom longitudinal member and to a left a knuckle for mounting a left wheel; and the first right transversal member extends slightly upwardly and away from the bottom cross-member passing over the front right bottom longitudinal member and to a right knuckle for mounting a right wheel.
  • the all-terrain vehicle comprises a second bottom cross-member sandwiching the first left and right transversal members between the first bottom crossmember, the second bottom cross-member securely fastening the first left and right transversal members, while allowing pivotal movement of the first left and right transversal members.
  • the front portion comprises a left and right bottom fasteners mounted in first and second holes of the first bottom cross-member
  • the left and right bottom fasteners comprise left and right bottom bolts comprising left and right distal threaded ends, the left and right mounting axes, and left and right bottom nuts, the left and right distal threaded ends of the left and right bottom bolts extending forwardly through the first and second holes, and outside of the first cross-member, and the second bottom crossmember being mounted on the left and right distal threaded ends.
  • the front portion comprises a left member extending upwardly from the left bottom distal end portion to a left top end portion; a right member extending upwardly from the right bottom distal end portion to a right top end portion; and a top crossmember extending between the left and right top ends.
  • the front portion comprises a middle cross-member above the first bottom cross-member, and extending between the left and right members, the middle cross-member comprising a mounting bracket for mounting a second left and right transversal members, the second left transversal member being pivotably mounted to the mounting bracket and extending away from the middle cross-member passing over the front left bottom longitudinal member and to the left knuckle, and the second right transversal member being pivotably mounted to the mounting bracket and extending away from the middle cross-member passing over the front right bottom longitudinal member and to the right knuckle.
  • the front portion comprises left and right shock absorbers extending upwardly from their respective left and right second left and right transversal members to the top cross-member, the left and right shock absorbers being pivotably mounted to the top cross-member, and upon pivotal movement of the first and second left and right transversal members, the left and right shock absorbers are compressed or expanded.
  • a rear suspension for an all-terrain vehicle including a main frame
  • the rear suspension comprising: a main swing arm including a left portion and a right portion, each of the left and right portions including a front end for pivotably mounting the main swing arm to the main frame of the all-terrain vehicle and a rear end, each of the left and right portions being configured to allow a torsional movement along a longitudinal axis of the left and right portions; a drive axle mounted to the rear end of the left and right portions; and at least one shock absorber having a first end mounted to the main swing arm and a second end mountable to the main frame of the all-terrain vehicle.
  • the main frame of the vehicle comprises left and right brackets, and the front ends of the left and right portions of the main swing arm are respectively pivotably mounted to the left and right brackets.
  • the at least one shock absorber comprises a left shock absorber and a right shock absorber.
  • the first end of the left shock absorber is mounted proximal to the rear end of the left portion of the main swing arm and the first end of the right shock absorber is mounted proximal to rear end of the right portion of the main swing arm.
  • the rear suspension further comprises a differential operatively coupled to the drive axle.
  • each of the left and right portions of the main swing arm comprise a front portion extending from the font end of to an intermediate location and rear portion extending from the intermediate location to the rear end.
  • the rear portion is generally T-shaped.
  • the drive axle comprises a sleeve portion, and wherein rear end of the rear portion is attached to the sleeve portion. In one feature, the rear end of the rear portion is welded to the sleeve portion.
  • the drive axle further comprises a shaft member rotatably received in the sleeve portion.
  • the front portion comprises a generally cylindrical tube extending from the front end to the intermediate location.
  • the front end of the front portion comprises a recess extending transverse to the longitudinal axis of the cylindrical tube, the recess being configured for receiving a bushing therein for securing the front portion to a corresponding bracket of the lower left tube of the main frame.
  • the bushing allows the corresponding left or right portion to pivot about a pivot axis P-P and a torsion movement about an axis LT-LT of the corresponding left or right portion relative to the bracket to which it is attached without compromising the pivoting movement about axis P-P.
  • the front and rear portions are two discrete components attached to one another.
  • the front and rear portions are attached to one another by welding.
  • the front and rear portions are attached to one another using nuts, bolts, brackets or collars.
  • the front and rear portions of the left portion are manufactured as a single piece.
  • the rear portion has a generally oblong cross-section.
  • the rear portion is sized, shaped and made of a material allowing a limited torsion of the rear portion about a longitudinal axis LT-LT.
  • At least one of the front portion and rear portion is made of StrenxTM 700 structural steel.
  • the StrenxTM 700 structural steel has a thickness of about 0.0551 inch (1 .4 mm).
  • an all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steer the front wheels of the all-terrain vehicle, the all-terrain vehicle comprising: a front end; a rear end; a service center compartment for providing a user with an access to at least one component of the all-terrain vehicle for maintenance thereof; and a service center cover for removably closing said service center compartment, the service center comprising an air entry into an airbox; the service center cover being located in front of the steering device.
  • the steering device comprises a handlebar.
  • the at least one component of the all-terrain vehicle is selected from a group comprising a portion of an airbox, a coolant bottle, a fuse box and a CVT air entry.
  • the service center cover is configured for easy removal. In one feature, the service center cover is removably securable to the service center compartment. In one feature, the service center cover is removably securable to the service center compartment using at least one of a toolless % turn, a toe-in, a snap engagement means, a hoop and loop fastener or a magnet. [0072] In one feature, the service center cover comprises at least one electrical component. In one feature, the at least one electrical component is selected from a group comprising a display for displaying information concerning systems of the all-terrain vehicle, a communication device to the driver and an electric outlet.
  • the all-terrain vehicle further comprises at least one wire extending from service center compartment and connectable to the service center cover for supplying the at least one electrical component with electric power or data.
  • the at least one wire comprises such a length as to allow the service center cover to be removed from the service center compartment and placed to one side thereof to allow access the at least one component within the service center compartment without having to disconnect the at least one wire.
  • the at least one wire is detachably connectable to at least one of the service center compartment and the service center cover.
  • the airbox comprises an airbox body provided with an airbox opening and defining an airbox compartment, an airbox cover removably mounted to the airbox body for closing the airbox opening, an air inlet allowing airto enterthe airbox body, an air outlet for allowing air to exit the airbox housing to reach an engine of the all-terrain vehicle and an air filter removably received into the airbox body through the airbox opening for filtering the air between the air inlet and the air outlet, the airbox opening and the airbox cover being located in the service center compartment and allowing for the air filter to be removed or installed via access to the service center compartment.
  • an all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steer the front wheels of the all-terrain vehicle
  • the all-terrain vehicle comprising: a front end; a rear end; an airbox comprising an airbox body provided with an airbox opening and defining an airbox compartment; an airbox cover removably mounted to the airbox body for closing the airbox opening; an air inlet allowing air to enter the airbox body; an air outlet for allowing air to exit the airbox housing to reach an engine of the all- terrain vehicle; and an air filter removably received into the airbox body through the airbox opening for filtering the air between the air inlet and the air outlet, the airbox opening and the airbox cover being in front of the steering device.
  • the steering device comprises a handlebar.
  • the all-terrain vehicle further comprises a service center compartment for providing a user with an access to at least one component of the all- terrain vehicle for maintenance thereof; and a service center cover for removably closing said service center compartment, the service center cover being located in front of the steering device, the airbox opening and the airbox cover located in the service center compartment being accessible to a user when the service center cover is removed.
  • the airbox body comprises a top portion and a bottom portion, the top portion being configured to receive the air inlet.
  • the top portion further comprises the airbox opening.
  • the airbox cover is configured to abut the airbox opening and to be removably secured to the airbox body.
  • the airbox cover is secured to the airbox body and held in place using securing devices configured to be manipulated and removed without the use of tools.
  • the securing devices comprise one or more over-center clips.
  • the airbox cover comprises at least one protrusion extending into the airbox body when the airbox cover is secured to the airbox body, the at least one protrusion holding the air filter in an installed position.
  • the at least one protrusion extends substantially vertically.
  • the at least one protrusion comprises at least one of a notch, a recess or an indentation for receiving therein a portion of the air filter to hold the air filter in the installed position.
  • the airbox further comprises a Helmholtz resonator received in the airbox body.
  • an all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steer the front wheels of the all-terrain vehicle
  • the all-terrain vehicle comprising: a front end; a rear end; a radiator mounted in front of the steering device and above the front wheels; a radiator cover for substantially covering the radiator, the radiator cover comprising: a pair of spaced-apart side covers extending generally vertically on each side of the radiator; a top cover extending between the spaced apart side covers and generally parallel to the radiator, the top cover being pivotably attached to one of the radiator and the spaced-apart side covers; an air opening defined on a front end of the radiator cover, the spaced-apart side covers and the top cover of the radiator cover contributing to generate a ram air effect of the air entering the air opening inside the radiator cover for ramming oncoming air onto the radiator during operation of
  • the radiator extends at a rearward angle between the front end of the all-terrain vehicle and the rear end thereof.
  • the rearward angle of the radiator varies between 30 and 60 degrees relative to a horizontal plane.
  • the spaced-apart side covers extend substantially vertically along a longitudinal axis of the all-terrain vehicle.
  • the all-terrain vehicle further comprises a pair of wheel fenders for covering the front wheels of the all-terrain vehicle, wherein each of the spaced-apart sides covers extend vertically from a corresponding wheel fender.
  • the top cover comprises a front end and a rear end, wherein the front end of the top cover is pivotably attached to the spaced-apart side covers.
  • the radiator cover further comprises at least one latching device for securing the top cover to the spaced-apart side covers and maintain the top cover in a closed position.
  • the radiator further comprises a removable toolkit.
  • the removable toolkit is removably securable to an inner face of the top cover.
  • Figure 1 is a rear, right perspective view of an ATV, in accordance with one embodiment of the present invention.
  • Figure 2 is a rear left perspective view the ATV shown in Figure 1 ;
  • Figure 3 is a front left perspective view of the ATV shown in Figure 1 ;
  • Figure 4 is a front right perspective view of the ATV shown in Figure 1 ;
  • Figure 5 is a left-side view of the ATV shown in Figure 1 ;
  • Figure 6 is a right-side view of the ATV shown in Figure 1 ;
  • Figure 7 is a front elevation view of the ATV shown in Figure 1 ;
  • Figure 8 is a rear elevation view of the ATV shown in Figure 1 ;
  • Figure 9 is a top plan view of the ATV shown in Figure 1 ;
  • Figure 10 is a rear right perspective view of a main frame for an ATV with a front bumper assembly and a front suspension attached thereto, in accordance with one embodiment
  • Figure 11 is a left-side view of the main frame, front bumper assembly and front suspension shown in Figure 10;
  • Figure 12 is a left-side view of the main frame, front bumper assembly and front suspension shown in Figure 10;
  • Figure 13 is a top plan view of the main frame, front bumper assembly and front suspension shown in Figure 10;
  • Figure 14 is a bottom plan view of the main frame, front bumper assembly and front suspension shown in Figure 10;
  • Figure 15 is a front elevation view of the main frame, front bumper assembly and front suspension shown in Figure 10;
  • Figure 16 is a rear elevation view of the main frame, front bumper assembly and front suspension shown in Figure 10;
  • Figure 17 is a front, left perspective view of the main frame, front bumper assembly and front suspension shown in Figure 10, with the front suspension attached thereto and the front bumper assembly detached therefrom;
  • Figure 18 is a rear right perspective view of the main frame, front suspension and front bumper assembly shown in Figure 17;
  • Figure 19 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 17;
  • Figure 20 is a right-side view of the main frame, front suspension and front bumper assembly shown in Figure 17;
  • Figure 21 is a top plan view of the main frame, front suspension and front bumper assembly shown in Figure 17;
  • Figure 22 is a bottom plan view of the main frame, front suspension and front bumper assembly shown in Figure 17;
  • Figure 23 is a rear right perspective view of a main frame for an ATV with a front bumper assembly and a front suspension attached thereto, in accordance with another embodiment
  • Figure 24 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 23;
  • Figure 25 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 23;
  • Figure 27 is a bottom plan view of the main frame, front suspension and front bumper assembly shown Figure 23;
  • Figure 28 is a front elevation view of the main frame, front suspension and front bumper assembly shown in Figure 23;
  • Figure 29 is a rear elevation view of the main frame, front suspension and front bumper assembly shown in Figure 23;
  • Figure 30 is a front, left perspective view of the main frame, front suspension and front bumper assembly shown in Figure 23;
  • Figure 31 is a front, left perspective view of the main frame, front suspension and front bumper assembly shown in Figure 23, with the front suspension attached thereto and the front bumper assembly detached therefrom;
  • Figure 32 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 31 ;
  • Figure 33 is a right-side view of the main frame, front suspension and front bumper assembly shown in Figure 31 ;
  • Figure 34 is a top plan view of the main frame, front suspension and front bumper assembly shown in Figure 31 ;
  • Figure 35 is a rear right perspective view of view of a main frame for an ATV with a front bumper assembly and a front suspension attached thereto, in accordance with another embodiment
  • Figure 36 is a left-side view of the frame, front bumper assembly and front suspension shown in Figure 35;
  • Figure 37 is a left-side view of the main frame, front bumper assembly and front suspension shown in Figure 35;
  • Figure 38 is a top plan view of the main frame, front bumper assembly and front suspension shown in Figure 35;
  • Figure 39 is a bottom plan view of the main frame, front bumper assembly and front suspension shown in Figure 35;
  • Figure 40 is a front elevation view of the main frame, front bumper assembly and front suspension shown in Figure 35;
  • Figure 41 is a rear elevation view of the main frame, front bumper assembly and front suspension shown in Figure 35;
  • Figure 42 is a front, left perspective view of the main frame, front bumper assembly and front suspension shown in Figure 35;
  • Figure 43 is a front, left perspective view of the main frame, front suspension and front bumper assembly shown in Figure 35, with the front suspension attached thereto and the front bumper assembly detached therefrom;
  • Figure 44 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 43;
  • Figure 45 is a right-side view of the main frame, front suspension and front bumper assembly shown in Figure 43;
  • Figure 46 is a top plan view of the main frame, front suspension and front bumper assembly shown in Figure 43;
  • Figure 47 is a front, right perspective view of a main frame for an ATV, in accordance with another embodiment
  • Figure 48 is a right-side view of the main frame shown in Figure 47;
  • Figure 49 is a left-side view of the main frame shown in Figure 47;
  • Figure 50 is a top plan view of the main frame shown in Figure 47;
  • Figure 51 is a top plan view of the main frame shown in Figure 47, along with an engine and a gas tank, in accordance with one embodiment;
  • Figure 52A is a front right perspective view of an engine for an ATV, in accordance with one embodiment;
  • Figure 52B is a front right perspective view of an engine for an ATV, in accordance with another embodiment
  • Figure 53 is a front right perspective view of the main frame shown in Figure 47 provided with engine mounting brackets for mounting the engine shown in Figure 52A into the engine compartment, in accordance with one embodiment;
  • Figure 54 is a front right perspective view of the frame shown in Figure 47 provided with engine mounting brackets for mounting the engine shown in Figure 52B into the engine compartment, in accordance with one embodiment;
  • Figure 55 is a rear right, exploded perspective view of the frame shown in Figure
  • Figure 56 is a rear right perspective view of the frame shown in Figure 53, with the engine shown in Figure 52A mounted into the engine compartment and the airbox mounted in a space located above the engine compartment, in accordance with one embodiment;
  • Figure 62 is a left-side view of the front suspension shown in Figure 59;
  • Figure 63 is an exploded view of an A-arm assembly for a front suspension of an ATV, in accordance with one embodiment;
  • Figure 64 is a rear right perspective view of a main frame for an ATV, with a front bumper assembly, a front suspension and a main swing arm of a rear suspension attached thereto, in accordance with one embodiment;
  • Figure 65 is a front left perspective view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
  • Figure 66 is a left-side view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
  • Figure 67 is a right-side view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
  • Figure 68 is a rear elevation view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
  • Figure 69 is a bottom view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
  • Figure 70 is an exploded view of a main swing arm of a rear suspension, in accordance with one embodiment of the present invention.
  • Figure 71 is a front left perspective view of the main swing arm shown in Figure 70, with rear shock absorbers and rear coil springs attached thereto, in accordance with one embodiment;
  • Figure 72 is a top plan view of the main swing arm, the rear shock absorbers and the rear coil springs shown in Figure 71 , with the rear wheels attached thereto, in accordance with one embodiment;
  • Figure 73 is a left-side view of the main swing arm, the rear shock absorbers and the rear coil springs and wheels shown in Figure 72;
  • Figure 74 is a rear right perspective view of a main frame for an ATV, with a front bumper assembly partially detached therefrom, and a main swing arm of the rear suspension in a full-bump position, an exhaust system and a gas tank attached thereto, in accordance with one embodiment;
  • Figure 75 is a top plan view of the main frame, front bumper assembly, main swing arm of the rear suspension, exhaust system and gas tank shown in Figure 74;
  • Figure 76 is a bottom plan view of the main frame, front bumper assembly, main swing arm of the rear suspension, exhaust system and gas tank shown in Figure 74;
  • Figure 77 is a rear elevation view of the main frame, front bumper assembly, main swing arm of the rear suspension, exhaust system and gas tank shown in Figure 74;
  • Figure 78 is a rear right perspective view of a main frame for an ATV, with a front bumper assembly detached therefrom, and a rear suspension, an exhaust system and a gas tank attached thereto, in accordance with another embodiment;
  • Figure 79 is a left-side view of the main frame, front bumper assembly, rear suspension, exhaust system and gas tank shown in Figure 78;
  • Figure 80 is a bottom view of the main frame, front bumper assembly, rear suspension, exhaust system and gas tank shown in Figure 78, showing a longitudinal axis Li -Li , in accordance with one embodiment
  • Figure 81 is a rear elevation view of the main frame, front bumper assembly, rear suspension, exhaust system and gas tank shown Figure 80;
  • Figure 82 is a front right perspective view of a rear suspension system for an ATV, in accordance with one embodiment
  • Figure 83 is an exploded view of a main swing arm of the rear suspension system shown in Figure 82, in accordance with one embodiment of the present invention.
  • Figure 84 is cross-section view of the main swing arm shown in Figure 83, with rear shock absorbers and rear coil springs attached thereto;
  • Figure 85 is a right side elevation view of a gas tank for an ATV, in accordance with one embodiment
  • Figure 86 is a front elevation view of the gas tank shown in Figure 85;
  • Figure 87 is a rear elevation view of the gas tank shown in Figure 85;
  • Figure 88 is a rear, right perspective view of the gas tank shown in Figure 85;
  • Figure 89 is a top plan view of the gas tank shown in Figure 85;
  • Figure 90 is a bottom plan view of the gas tank shown in Figure 85;
  • Figure 91 is a left-side view of the gas tank shown in Figure 85;
  • Figure 92 is a rear left perspective view of an engine, a muffler and a gas tank for an ATV, in accordance with one embodiment
  • Figure 93 is a right-side view of the engine, a muffler and gas tank shown in Figure 92;
  • Figure 94 is a bottom plan view of the engine, a muffler and gas tank shown in Figure 92;
  • Figure 95 is top plan view of the engine, a muffler and gas tank shown in Figure 92;
  • Figure 96 is left side view of the gas tank sown in Figure 92 mounted to a main frame of an ATV, in accordance with one embodiment
  • Figure 97 is a rear, left perspective view of the main frame shown in Figure 10, with an alternate embodiment of a rear suspension attached thereto;
  • Figure 98 is a rear, left, partially exploded view of the main frame and rear suspension shown in Figure 97;
  • Figure 99 is a rear, right, view of the main frame and rear suspension shown in Figure 97;
  • Figure 100 is a rear, right, partially exploded view of the main frame and rear suspension shown in Figure 97;
  • Figure 101 is a left-side view of the main frame and rear suspension shown in Figure 97;
  • Figure 102 is a left side, partially exploded view of the main frame and rear suspension shown in Figure 97;
  • Figure 103 is a rear right perspective view of a rear suspension subframe, in accordance with one embodiment of the present invention.
  • Figure 104 is a rear left perspective view of the rear suspension subframe shown in Figure 103;
  • Figure 105 is a top plan view of the rear suspension subframe shown in Figure 103;
  • Figure 106 is a left-side view of the rear suspension subframe shown in Figure 103;
  • Figure 107 is a rear elevation view of the rear suspension subframe shown in Figure 103;
  • Figure 108 is a front elevation view of the rear suspension subframe shown in Figure 103;
  • Figure 109 is a top plan view of a rear left suspension for an ATV, in accordance with one embodiment
  • Figure 110 is a bottom plan view of the rear left suspension shown in Figure 109;
  • Figure 11 1 is an enlarged rear, left, partially exploded view of the rear suspension subframe shown in Figure 103 and the rear left suspension shown in Figure 109;
  • Figure 112 is an enlarged left, partially exploded side view of the rear portion of the main frame, the rear suspension subframe shown in Figure 102;
  • Figure 113 is a rear right perspective view of a main frame for an ATV, with a portion of a front bumper assembly, a rear the rear suspension in a showroom configuration, and a partially exploded hitch assembly attached thereto, in accordance with one embodiment;
  • Figure 114 is a rear right perspective view of a portion of the main frame, a portion of the rear suspension in a showroom configuration and the hitch assembly shown in Figure 113, with a hitch positioned in a hitch receiver, in accordance with one embodiment;
  • Figure 115 is a perspective view of the frame shown in Figure 114, with the portion of the rear suspension shown in a full-bump configuration;
  • Figure 116 is a rear elevation view of the frame as shown in Figure 114;
  • Figure 117 is a rear elevation view of the frame as shown in Figure 115;
  • Figure 118 is a rear right perspective view of a rear portion of the main frame, the rear suspension and the hitch assembly shown in Figure 113, with the hitch assembly partially exploded;
  • Figure 119 is a partial enlarged view of the main frame, the rear suspension and the hitch assembly shown in Figure 118;
  • Figure 120 is another rear right perspective view of a rear portion of the main frame, the rear suspension and the hitch assembly shown in Figure 113, with the hitch assembly partially exploded;
  • Figure 121 is another partial enlarged view of the main frame, the rear suspension and the hitch assembly shown in Figure 118;
  • Figure 122 is a right-side view of a rear portion of the main frame and hitch assembly shown in Figure 113, with a right proximal end of the rear portion of the main frame shown in cross-section;
  • Figure 122A is an enlarged, cross-sectional view ofthe right proximal end of the rear portion of the main frame as shown in Figure 122;
  • Figure 123 is a bottom plan view of the rear portion of the frame as shown in Figure 114;
  • Figure 124 is a bottom, exploded view a portion of the proximal end of the main frame shown in Figure 113;
  • Figure 125 is a left-side view of the main frame, a portion of a front left suspension and of a steering assembly, in accordance with one embodiment, with the steering assembly in a full left steer position and the front left suspension in a showroom position;
  • Figure 126 is a rear right perspective view of a steering assembly and a portion of the front left suspension, in accordance with one embodiment, with the steering assembly in a full-left steer position and the front left suspension in a showroom position;
  • Figure 127 is a right-side view of a steering assembly and a portion of the main frame, in accordance with one embodiment
  • Figure 128 is an enlarged partial right exploded view of the steering assembly shown in Figure 127 and a portion of the front left suspension, in accordance with one embodiment
  • Figure 129 is an enlarged perspective view of the steering assembly and a portion of the front left suspension shown in Figure 126;
  • Figure 130 is a bottom plan view of a portion of the steering assembly, a portion of the main frame and a portion of the front suspension in accordance with one embodiment, with the steering assembly in a full left steer position and the suspension in a showroom position;
  • Figure 131 is an enlarged perspective view of the steering assembly and a portion of the front left suspension in accordance with one embodiment, with the steering assembly in a full-left steer position and the front left suspension in a full-droop position;
  • Figure 132 is another perspective view of the steering assembly and a portion of the front left suspension shown in Figure 131 , with the steering assembly in a full-left steer position and the front left suspension in a full-droop position;
  • Figure 133 is a bottom plan view of a portion of the steering assembly, a portion of the main frame and a portion of the front suspension in accordance with one embodiment, with the steering assembly in a full left steer position and the suspension in a full-droop position;
  • Figure 134 is a rear, left, exploded view of a portion of the steering assembly and of a portion of the main frame, in accordance with one embodiment of the present invention
  • Figure 135 is a left-side view of a main frame and of an airbox attached thereto, in accordance with one embodiment;
  • Figure 136 is a rear right perspective view of the main frame and airbox shown in Figure 135;
  • Figure 137 is a top plan view of the main frame and airbox shown in Figure 135;
  • Figure 138 is a rear right perspective, exploded view of an airbox, in accordance with one embodiment
  • Figure 139 is a rear, exploded view of the airbox shown in Figure 138;
  • Figure 140 is a top plan view of the airbox shown in Figure 138;
  • Figure 141 is a bottom plan view of the airbox shown in Figure 138;
  • Figure 142 is a front, exploded view of the airbox shown in Figure 138;
  • Figure 143 is a front left perspective view of an ATV comprising a service center and airbox, in accordance with one embodiment
  • Figure 144 is a left-side view of the ATV shown in Figure 143;
  • Figure 145 is the ATV of Figure 144 with a service center cover removed, in accordance with one embodiment
  • Figure 146 is a partial, enlarged top view of a portion ofthe ATV shown in Figure 143 with the service center cover removed, for better showing the service center and airbox configurations, in accordance with one embodiment;
  • Figure 147 is a front right perspective view of the service center and airbox shown in Figure 146;
  • Figure 148 is a front left perspective view of engine components, a handlebar and a seat of the ATV of Figure 143, in accordance with one embodiment
  • Figure 149 is a front right perspective view of the engine components, the handlebar and the seat shown in Figure 148;
  • Figure 150 is a left-side view of an airbox for an ATV, in accordance with one embodiment
  • Figure 151 is a right-side view of the airbox shown in Figure 150;
  • Figure 152 is a top view of the airbox shown in Figure 150;
  • Figure 153 is a front view of the airbox shown in Figure 150;
  • Figure 154 is a partially exploded, left side view of the airbox shown in Figure 150, for better showing an airbox cover in a removed position;
  • Figure 155 is an exploded left side view of the airbox shown in Figure 150;
  • Figure 156 is a left a cross-section across the airbox shown in Figure 153, taken along line 156-156, with an air filter installed;
  • Figure 157 is a right a cross-section of the airbox shown in Figure 150 mounted in an ATC, with the airbox cover removed and the air filter installed;
  • Figure 158 is a cross-section view of the airbox shown in Figure 157, with the airbox cover removed and the air filter in the process of being removed;
  • Figure 159 is a left-side view of the ATV shown in Figure 145, with the air filter removed via access to the service center;
  • Figure 160 is a front left perspective view of an ATV, in accordance with another embodiment
  • Figure 161 is a partial, enlarged view of the ATV shown in Figure 160, for better showing a radiator cover, in accordance with one embodiment
  • Figure 162 is a partial, enlarged top view of the ATV shown in Figure 160, for better showing the radiator cover;
  • Figure 163 is a front left perspective view of the ATV shown in Figure 160, with the radiator cover in an open position;
  • Figure 164 is a partial, enlarged front perspective view of the ATV shown in Figure 163, for better showing features of the radiator cover in open position;
  • Figure 165 is a left-side view of the ATV shown in Figure 163;
  • Figure 166 is a top view of the ATV shown in Figure 163;
  • Figure 167 is a front right perspective view a radiator cover for an ATV, in accordance with one embodiment;
  • Figure 168 is a bottom view of the radiator cover shown in Figure 167 and a toolkit secured to an inside face of the cover, in accordance with one embodiment;
  • Figure 169 is another bottom view of the radiator cover shown in Figure 167, with the toolkit removed from the inside face;
  • Figure 170 is a left-side view of a radiator, portion of a radiator cover, an engine, certain engine components and a seat of an ATV in accordance with one embodiment, showing a flow of air relative to the radiator and radiator cover;
  • Figure 171 is a top view of the radiator, the portion of a radiator cover, the engine, certain engine components and the seat shown in Figure 170;
  • Figure 172 is a left-side view of an ATV in a packing configuration in a crate, in accordance with one embodiment.
  • Figure 173 is a front elevation view of the ATV in the packing configuration shown in Figure 172.
  • the ATV 10 comprises a main frame 12, an engine 14 (see Figures 5 and 6) mounted to the main frame 12, a front bumper assembly 13, a pair of front wheels 16a, 16b mounted to the main frame 12 via a front suspension 18 and operatively connected to the engine 14 via a front transmission 20 ( Figures 3 and 4), and a pair of rear wheels 22a, 22b mounted to the main frame 12 via a rear suspension 24 and operatively connected to the engine 14 via a rear transmission 26 ( Figures 2 and 8).
  • the ATV 10 also comprises a steering assembly 28 mounted to the frame 12 and operatively connected to the front wheels 16a, 16b of the ATV 10 for allowing a user to steer the ATV 10, as well as a seat 30 and left and right footrests 32a, 32b ( Figures 1 to 6 and 9) for allowing the user to sit on the ATV 10.
  • a steering assembly 28 Provided on the steering assembly 28 are controls (e.g. as seen on Figure 1 , throttle control 29 and brake lever 31).
  • a rear brake control 33 is provided on the steering assembly 28 operatively connected to the front wheels 16a, 16b of the ATV 10 for allowing a user to steer the ATV 10, as well as a seat 30 and left and right footrests 32a, 32b ( Figures 1 to 6 and 9) for allowing the user to sit on the ATV 10.
  • controls e.g. as seen on Figure 1 , throttle control 29 and brake lever 31.
  • a rear brake control 33 adjacent to the right footrests 32b, is a rear brake
  • the main frame 12 of the ATV includes a pair of longitudinally extending, left and right lower tubes 100,102 defining the lower portion of the main frame, as well as a left, generally Y-shaped tube 104 and a right upper tube 106.
  • the longitudinally extending left and right lower tubes 100, 102 and the longitudinally extending left and right upper tubes 104, 106 will sometimes be referred to as “bottom longitudinal members” 100, 102 or “top longitudinal members” 104, 106, being understood that the terms “lower tubes” and “upper tubes” are used interchangeably with “bottom longitudinal members” and “top longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
  • connecting the left lowertube 100 and the left upper tube 104 are front and rear, left upwardly extending tubes 108, 1 10.
  • connecting the right lower tube 102 and the right upper tube 106 are front and rear right upwardly extending tubes 112, 114.
  • Extending between the lowertubes 100 and 102 is a plurality of lower cross-members 116a-1 16d (best shown in Figure 14), while upper tubes 104, 106 are connected by upper cross-members 118a-118c (best shown in Figure 13).
  • the front upwardly extending tubes 108 and 112 are connected to one another via cross-members 1 19a, 119b.
  • lower tubes 100, 102, upper tubes 104, 106, front and rear upwardly extending tubes 108, 1 10, 112, 114 and cross-members 116a-116d, 118a-118c and 119a-119b define a frame engine compartment or housing 120 (see Figures 10 to 12) for receiving the engine 14 of the ATV 10, as well as a portion of the front and/or rear transmissions 20, 26, as it will be described in greater detail below.
  • the term “engine compartment” is used to broadly define an area or space in which the engine of the ATV can be received.
  • this term should be interpreted to include any engine cradle, engine bay, engine housing or any other term that is used to designate such an area for receiving an engine in an ATV.
  • brackets, bushings, rubber, support plates, bolts and the like can be used to secure the engine 14 to main frame 12 while reducing vibrations caused by the operation of engine 14.
  • the right top longitudinal member 106 is at a first distance di from the right bottom longitudinal member 102 and the left top longitudinal member 104 is at a second distance from the left bottom longitudinal member 100. It is understood that the first and second distances di and d 2 are measured at corresponding left and right positions along the longitudinal axis. In the illustrated embodiment, the first distance di is greater than the second distance d 2 and the left and right bottom longitudinal members 100, 102 and the left and right top longitudinal members 104, 106 define therebetween the engine compartment, which is adapted to receive engines of different sizes while defining a space above the left top longitudinal member 104, the space being adapted to receive a component or components of the ATV. In some embodiments, the first distance di may be between about 65 cm and about 45 cm and the second distance d 2 may be between about 60 cm and about 40 cm, as described in greater details below.
  • FIG 17 extending downwardly from cross-member 118a is a left front tube 1 17.
  • Left front tube 1 17 has a top end 121 connected to cross-member 118a, at the junction of upwardly extending left tube 108, and a bottom end 123 attached to a front end 125 of left lower tube 100.
  • a right-front tube 127 extends downwardly from cross-member 1 18a.
  • Right front tube 127 has a top end 129 connected to cross-member 118a, at the junction of upwardly extending right tube 112, and a bottom end 131 attached to a front end 133 of right lower tube 102.
  • bracket 135 has a lower plate member 137, and a front flange 139 extending upwardly at the front of lower plate member 137, perpendicularly thereto.
  • front flange 139 of bracket 135 is provided with holes (not shown) for mounting a portion of the front suspension 18 to the main frame 12.
  • left footrest subframe 130 for supporting footrest 32a.
  • right footrest subframe 132 for supporting footrest 32b.
  • left footrest subframe 130 has a generally U-shape and comprises a front tube 134, a bottom tube 136 and a rear tube 138.
  • the front tube 134 has a top end 140 attached to left, front upwardly extending tube 108, at the junction of left upper tube 104 and upper cross-member 1 18a, and a bottom end 142.
  • the front tube 134 is curved and extends generally downwardly and rearwardly. At the bottom end 142 thereof, front tube 134 is attached to a front end 144 of the bottom tube 136, while a rear end 146 of the bottom tube 136 is attached to the rear tube 138. More specifically, the rear tube 138 comprises a lower end 150 attached to the rear end 146 of the bottom tube 136, and a generally Y-shaped top end 152 having a main portion 154 attached to a lower left tube 156 of a rear fender portion 158, and a secondary portion 160 attached to an upper left tube 162 of the rear fender portion 158.
  • the right footrest subframe 132 has a generally U-shape and comprises a front tube 164, a bottom tube 166 and a rear tube 168.
  • the front tube 164 has a top end 170 attached to right, front upwardly extending tube 110, at the junction of right upper tube 106 and upper cross-member 118a, and a bottom end 172. Moving from the top end 170 to the bottom end 172, the front tube 164 is curved and extends generally downwardly and rearwardly. At the bottom end 172 thereof, the front tube 164 is attached to a front end 174 of the bottom tube 166, while a rear end 167 of the bottom tube 166 is attached to the rear tube 168.
  • the rear tube 168 comprises a lower end 171 attached to the rear end 167 of the bottom tube 166, and a generally Y-shaped top end 173 having a main portion 175 attached to a lower right tube 176 of the rear fender portion 158, and a secondary portion 180 attached to an upper right tube 182 of the rear fender portion 158.
  • the left and right upper tubes 162, 182 will sometimes be referred to as “longitudinal members” 162, 182 being understood that the terms “upper tubes” are used interchangeably with “longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
  • left and right footrest subframes 130, 132 each defines a generally U-shape when seen from the top ( Figure 13) or from the bottom ( Figure 14).
  • a pair of cross-members 184a, 184b extend between left lower tube 100 and bottom tube 136 of left footrest subframe 130.
  • a pair of cross-members 186a, 186b extend between right lower tube 102 and bottom tube 166 of right footrest sub-frame 132.
  • left and right subframes 130, 132 provide a structure or frame onto which can be mounted left and right footrests 32a, 32b. Furthermore, as it will be appreciated, left and right footrest subframes 130, 132 contribute to the overall rigidity of the main frame 12.
  • the rear fender portion 158 comprises left and right lower tubes 156, 176, as well as, left and right upper tubes 162, 182.
  • Left lower tube 156 comprises a front end 190 attached to the left upwardly extending tube 110 (see Figure 11), as well as a rear end 192.
  • right lower tube 176 comprises a front end 194 attached to the right upwardly extending tube 114, and a rear end 196 (see Figure 12).
  • the left and right lower tubes 156, 176 converge toward one another, from the front ends 190, 194 to the rear ends 192, 196 thereof, while being curved and extending generally upwardly when seen from the side (e.g.
  • FIG. 11 to accommodate the rear drive train 200, as it will become apparent below.
  • connecting the rear ends 192, 196 of left and right lower tubes 156, 176 of the rear fender portion 158 is a lower, rear cross-member 202.
  • lower, rear cross-member 202 partially projects sidewardly from the right lower tube member 176.
  • left and right lower tubes 156, 176 are also connected to one another by way of cross-member 204a and 204b, which extend respectively between left and right, upwardly extending tubes 110, 1 14, at the junction of front ends 190, 194, and in an intermediate location between the front ends 190, 194 and the rear ends 192, 196 of left and right lower tubes 156, 176 (best shown in Figure 14).
  • left upper tube 162 of the rear fender portion 158 comprises a front end 206 and a rear end 208, the front end 206 being attached to crossmember 118c.
  • right upper tube 182 of the rear fender portion 158 comprises a front end 210 and a rear end 212, the front end 210 also being attached to cross-member 118c.
  • the left and right upper tubes 162, 182 of the rear fender portion 158 diverge away from one another, from their respective front ends 206, 210, toward their rear ends 208, 212.
  • Connecting the rear ends 208, 212 of the left and right upper tubes 162, 182 is an upper rear cross-member 214.
  • the left and right upper tubes 162, 182 are also connected to one another by way of cross-members 216a, 216b, which extends in an intermediate location between the front ends 206, 210 and the rear ends 208, 212 of the left and right upper tubes 162, 182. Extending between the lower and upper cross-members 202 and 214 are two angularly extending tubes 218, 220 (also shown in Figures 14 and 16).
  • the rear fender portion 158 of the main frame 12 also comprises a right gas tank protecting subframe 222 for protecting a gas tank 201 (not shown in Figure 12) from impacts during the operation of the ATV 10, as it will become apparent below.
  • this gas tank protecting subframe 222 comprises a first tube member 224 having a front end 226 attached to the right upper tube 182 of the rear fender portion 158. It also comprises second, third and fourth tube members 228, 230, 231 respectively, for sequentially connecting the first tube member 224 to the right lower tube 176 of the rear fender section 158, at the junction of lower cross-member 202.
  • front bumper assembly 13 will now be described in accordance with one embodiment. As it will become apparent below, and as shown in Figures 19 and 20, in this embodiment, the front bumper assembly 13 is configured to be assembled to the main frame 12 using threaded fasteners 232a, 232b and 234a, 234b, which are also used to mount portions of the front suspension 18 between the front bumper assembly 13 and the main frame 12, as it will become apparent below.
  • front bumper assembly 13 comprises left and right curved tubes 236, 238, each tube having a top end 240, 242 and a lower end 244, 246.
  • the left and right front curved tubes 236, 238 are attached to one another by way of a top cross-member 248.
  • a mounting plate 250 Connecting the lower ends 244, 246 of the left and right curved tube 236, 238 is a mounting plate 250.
  • Mounting plate 250 comprises a pair of holes 252a, 252b (Only hole 252b being shown in Figures 17 and 18) for receiving therethrough a corresponding pair of fasteners 232a, 232b for mounting the lower end of the front bumper assembly 13 to the left and right lower tubes 100, 102 of the main frame 12, as it will be described in greater detail below.
  • the front bumper assembly 13 further comprises an intermediate cross-member 254, extending between the left and right curved tubes 236, 238, in an intermediate location between the top ends 240, 242 and the lower ends 244, 246 thereof, as well as a protective plate 256 extending between the mounting plate 250 and the intermediate cross-member 254.
  • left and right rack support tubes 258, 260 Extending proximate to the top ends 240, 242 of left and right curved tubes 236, 238, slightly below the top cross-member 248, are left and right rack support tubes 258, 260. As best shown Figures 19 and 20, respectively, left and right rack support tubes 258, 260 extend generally perpendicular to the top end 240, 242 of the left and right curved tubes 236, 238 toward the rear end of the ATV 10. As such, and referring to Figure 19 the left rack support tube 258 comprises a front end 262 connecting the left curved tube 236, and a rear end 264. Likewise, and referring now to Figure 20 the right rack support tube 260 comprises a front end 266 connecting the right front tube 238, and a rear end 268.
  • each of the left and right rack support tube 258, 260 is provided with a generally U-Shaped bracket 270, 272, from which extends a crossmember 274.
  • cross-member 274 comprises a pair of spaced apart downwardly extending tubes 276, 278 secured to the U-shaped brackets 270, 272, and a cross-tube 280 extending therebetween.
  • left and right securing brackets 286, 288 (shown in Figure 21), the securing brackets 286, 288 each comprising a hole (not shown) for receiving therethrough a threaded fastener 234a, 234b (shown in Figures 19 and 20) for securing the top end of the bumper assembly 13 to the cross-tube 118a of the main frame 12.
  • the main frame 10012 includes a pair of longitudinally extending, left and right lower tubes 10100,10102 defining the lower portion of the main frame, as well as a left, generally Y- shaped upper tube 10104 and a right upper tube 10106.
  • the longitudinally extending left and right lower tubes 10100, 10102 and the longitudinally extending left and right upper tubes 10104, 10106 will sometimes be referred to as “bottom longitudinal members” 10100, 10102 or “top longitudinal members” 10104, 10106, being understood that the terms “lower tubes” and “upper tubes” are used interchangeably with “bottom longitudinal members” and “top longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
  • connecting the left lower tube 10100 and the left upper tube 10104 are front and rear, left upwardly extending tubes 10108, 10110.
  • connecting the right lower tube 10102 and the right upper tube 10106 are front and rear right upwardly extending tubes 10112, 10114.
  • Extending between the lowertubes 10100 and 10102 is a plurality of lower cross-members 10116a-10116d (best shown in Figure 27), while upper tubes 10104, 10106 are connected by upper cross-members 10118a-10118d (best shown in Figure 26).
  • crossmembers 118a-118c of frame 12 are all tubular members extending generally perpendicular to the longitudinal axis of the ATV
  • cross-members 101 18a-101 18d of frame 10012 have a slightly different configuration. More specifically, cross-members 10118a and 10118d are tubular members extending along a transverse axis (i.e., generally perpendicular to the longitudinal axis of the ATV) while cross-member 101 18b extends with an angle relative to the transverse axis.
  • cross-member 10118c is made of a stamped sheet of metal.
  • cross-members 10118a-10118d can vary without departing from the scope of this embodiment, where some of all of them could all be made of tubular members or stamped sheet of metals, and could adopt different shapes or different angles relative to the longitudinal or transverse axis of the ATV 10.
  • Extending between cross-members 10118a and 10118b is a longitudinal tubular member 10115, configured for attaching the steering column thereto, as it will become apparent below.
  • the front upwardly extending tubes 10108 and 10112 are connected to one another via cross-members 10119a, 10119b.
  • lower tubes 10100, 10102, upper tubes 10104, 10106, front and rear upwardly extending tubes 10108, 10110,10112, 101 14 and cross-members 10116a-101 16d, 10118a-10118d and 101 19a- 10119b define an engine compartment 10120 (see Figures 23 to 25) for receiving the engine (e.g., engine 14 of the ATV 10), as well as a portion of the front and/or rear transmissions (e.g., transmission 20, 26), as it will be described in greater detail below.
  • FIG. 30 extending downwardly from cross-member 10118a is a left front tube 101 17.
  • Left front tube 10117 has a top end 10121 connected to crossmember 101 18a, at the junction of upwardly extending left tube 10108, and a bottom end 10123 attached to a front end 10125 of left lower tube 10100.
  • a right-front tube 10127 extends downwardly from cross-member 10118a.
  • Right front tube 10127 has a top end 10129 connected to cross-member 10118a, at the junction of upwardly extending right tube 10112, and a bottom end 10131 attached to a front end 10133 of right lower tube 10102.
  • the right top longitudinal member 10106 is at a first distance di from the right bottom longitudinal member 10102 and the left top longitudinal member 10104 is at a second distance d 2 from the left bottom longitudinal member 10100. It is understood that the first and second distances di and d 2 are measured at corresponding left and right positions along the longitudinal axis. In the illustrated embodiment, the first distance di is greater than the second distance d 2 and the left and right bottom longitudinal members 10100, 10102 and the left and right top longitudinal members 10104, 10106 define therebetween the engine compartment, which is adapted to receive engines of different sizes while defining a space above the left top longitudinal member 10104, the space being adapted to receive a component or components of the ATV. In some embodiments, the first distance di may be between about 65 cm and about 45 cm and the second distance d 2 may be between about 60 cm and about 40 cm, as it will be best described below.
  • a left footrest subframe 10130 for supporting footrest (e.g., footrest 32a).
  • a right footrest subframe 10132 for supporting footrest (e.g., footrest 32b), which extends sidewardly from the right lower and upper tubes 10102, 10106.
  • Left and right footrest subframes 10130 and 10132 being similar to subframes 130 and 132 of frame 12, the description of subframes 130 and 132 is also applicable to subframes 10130 and 10132 respectively, with proper adaptations.
  • left and right subframes 10130, 10132 provide a structure or frame onto which can be mounted left and right footrests (e.g., left and right footrests 32a, 32b). Furthermore, as it will be appreciated, left and right footrest subframes 10130, 10132 contribute to the overall rigidity of the main frame 10012. [00299] Returning now to Figures 24 and 25, the rear fender portion 10158 comprises left and right lower tubes 10156, 10176, as well as, left and right upper tubes 10162, 10182.
  • left and right upper tubes 10162, 10182 will sometimes be referred to as “longitudinal members” 10162, 10182 being understood that the terms “upper tubes” are used interchangeably with “longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
  • Left lower tube 10156 comprises a front end 10190 attached to the left upwardly extending tube 10110 (see Figure 24), as well as a rear end 10192.
  • right lower tube 10176 comprises a front end 10194 attached to the right upwardly extending tube 101 14, and a rear end 10196 (see Figure 25).
  • the left and right lower tubes 10156, 10176 are slightly curved toward the right and converge toward one another, from the front ends 10190, 10194 to the rear ends 10192, 10196 thereof, while being curved and extending generally upwardly when seen from the side (e.g. Figures 24 and 25) to accommodate the rear drive train (e.g., drive trains 200 or 10200), as it will become apparent below.
  • the rear drive train e.g., drive trains 200 or 10200
  • left and right lower tubes 10156, 10176 are also connected to one another by way of crossmembers 10204a and 10204b, which extend respectively between left and right, upwardly extending tubes 101 10, 101 14, at the junction of front ends 10190, 10194, and in an intermediate location between the front ends 10190, 10194 and the rear ends 10192, 10196 of left and right lower tubes 10156, 10176 (best shown in Figure 27).
  • left upper tube 10162 of the rear fender portion 10158 comprises a front end 10206 and a rear end 10208, the front end 10206 being attached to the left upwardly extending tube 101 10.
  • right uppertube 10182 ofthe rearfender portion 10158 comprises a front end 10210 and a rear end 10212, the front end 10210 being attached right upwardly extending tube 101 14.
  • the left and right upper tubes 10162, 10182 of the rear fender portion 10158 diverge away from one another, from their respective front ends 10206, 10210, toward their rear ends 10208, 10212.
  • Connecting the rear ends 10208, 10212 of the left and right upper tubes 10162, 10182 is an upper rear cross-member 10214.
  • the left and right upper tubes 10162, 10182 are also connected to one another by way of a cross-member 10216, which extends in an intermediate location between the front ends 10206, 10210 and the rear ends 10208, 10212 of the left and right upper tubes 10162, 10182.
  • left and right angulartubes 10151 , 10153 Extending between the left and right upper tubes 10162,10182, and the left and right lowertubes 10156, 10176, respectively, are left and right angulartubes 10151 , 10153 ( Figure 24, 25 and 29).
  • Left angular tube 10151 comprises a top portion 10154 and a bottom portion 10134.
  • right angular tube 10153 comprises a top portion 10137 and a bottom portion 10138.
  • a lower cross-member 10202 Extending at a bottom end of the bottom portions 10134, 10138 of the left and right angular tubes 10151 , 10153 is a lower cross-member 10202. As best shown in Figures 24 and 25, the bottom portions 10134, 10138 and the lower cross-member 10202 extend below the rear ends of the left and right lower tubes 10156, 10176. Secured to the lower cross-member 10202 and extending toward the front of the fender portion 10158, is a sleeve 10228 for receiving a towing attachment.
  • the sleeve 10228 comprises a rear end 10229 secured to the lower cross-member 10202, and a front 10231 end connected to the left and right lower tubes 10156 and 10176 by way of left and right tubes and bracket assemblies 10232, 10233.
  • the rear fender portion 10158 of the main frame 10012 also comprises a gas tank protecting subframe 10222 for protecting a gas tank 10201 (not shown in Figure 25) from impacts during the operation of the ATV 10, as it will become apparent below.
  • this gas tank protecting subframe 10222 comprises a first tube member 10224 attached to the right upper tube 10182 of the rear fender portion 10158. It also comprises second tube members 10225, for connecting the first tube member 10224 to the right angular tube 10153, proximal to the junction between the top and bottom portions 10137, 10138 thereof.
  • the rear rack 10159 comprises a peripheral tube 1200 defining a periphery and having a front end 1202, a back end 1204 and left and right side ends 1206, 1208 (see Figure 26), which together define a space 1210 for receiving therein a storage compartment 1212 (see Figures 1 to 4). Extending on the left and right side ends 1206, 1208, and connecting the front and back ends 1202, 1204 of the peripheral tube 1200, are left and right reinforcing tubes 1214, 1216, as well as left and right reinforcing plates 1218, 1220.
  • the peripheral tube 1200 is bent downwardly such that when the rear rack 10159 is properly positioned on the rear fender portion 10158, the peripheral tube 1200 is proximal to the left and right upper tubes 10162 and 10182, where brackets 1222 and 1224 are provided to secure the peripheral tube 1200 to the left and right upper tubes 10162 and 10182 (see Figures 23 to 25).
  • the peripheral tube 1200 is provided with left and right, downwardly extending tubes 1226, 1228, for connecting the peripheral tube 1200 to the upper rear cross-member 10214.
  • front bumper assembly 10013 is configured to be assembled to the main frame 10012 using threaded fasteners 10232a, 10232b and 10234a, 10234b, which are also used to mount portions of the front suspension (e.g., front suspension 18) between the front bumper assembly 10013 and the main frame 10012, as it will become apparent below.
  • front bumper assembly 10013 comprises left and right curved tubes 10236, 10238, each tube having a top end 10240, 10242 and a lower end 10244, 10246.
  • the left and right front curved tubes 10236, 10238 are attached to one another by way of a top cross-member 10248 (shown in Figure 31). Connecting the lower ends 10244, 10246 of the left and right curved tube 10236, 10238 is a mounting plate 10250, similar to mounting plate 250 of bumper assembly 13.
  • the front bumper assembly 10013 further comprises an intermediate cross-member 10254, extending between the left and right curved tube 10236, 10238, in an intermediate location between the top end 10240, 10242 and the lower end 10244, 10246 thereof, as well as a protective plate 10256 extending between the mounting plate 10250 and the intermediate cross-member 10254.
  • the top rack portion 1300 comprises a tube 1302 defining a periphery and having a front end 1304, a back end 1306 and left and right side ends 1308, 1310 which together define a space 1312 for receiving a storage compartment 1313 (shown in Figures 1 to 4).
  • a left bracket mounting tube 1322 extending from the left reinforcement tube 1316, toward the right and slightly downwardly, is a left bracket mounting tube 1322, having a first end 1324 connected to the left reinforcement tube 1316, and a second end 1326. Connecting the second end 1326 of the left bracket mounting tube 1322 to the rear end 1306 of the peripheral tube 1302 is a connecting member 1328.
  • a right bracket mounting tube 1330 Extending from the right reinforcement tube 1318, toward the left and slightly downwardly, is a right bracket mounting tube 1330, having a first end 1332 connected to the right reinforcement tube, and a second end 1334. Connecting the second end 1334 of the right bracket mounting tube 1330 to the rear end of the peripheral tube 1302 is another connecting member 1336.
  • left and right bracket mounting tubes 1322 and 1330 Provided to the left and right bracket mounting tubes 1322 and 1330 are left and right securing brackets 10286, 10288 (shown in Figures 32 and 33), the securing brackets 10286, 10288 each comprising a hole (not shown) for receiving therethrough a threaded fastener 10234a, 10234b (shown in Figures 31 to 33) for securing the top end of the bumper assembly 10013 to the cross-tube 10118a of the main frame 10012.
  • the main frame 35012 includes a pair of longitudinally extending, left and right lower tubes 35100, 35102 defining the lower portion of the main frame, as well as a left upper tube 35104 and a right upper tube 35106.
  • the longitudinally extending left and right lower tubes 35100, 35102 and the longitudinally extending left and right uppertubes 35104, 35106 will sometimes be referred to as “bottom longitudinal members” 35100, 35102 or “top longitudinal members” 35104, 35106, being understood that the terms “lower tubes” and “upper tubes” are used interchangeably with “longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
  • FIG. 36 connecting the left lower tube 35100 and the left upper tube 35104, are front and rear, left upwardly extending tubes 35108, 35110.
  • FIG. 37 connecting the right lower tube 35102 and the right upper tube 35106 are front and rear right upwardly extending tubes 35112, 35114.
  • Extending between the lowertubes 35100 and 35102 is a plurality of lower cross-members 35116a-35116f (best shown in Figure 39).
  • One or more of lower cross-members 35116a- 35116f may extend from the left or right lower tubes 35100 and 35102 at an angle other than a right angle.
  • Two or more cross-members 35116a-35116f may intersect each other and/or extend between each other.
  • crossmember 35116e extends between the right bottom tube 35102 and bottom cross-member 35116f
  • bottom cross-member 351 16d extends between left lower tube 35100 and bottom cross-member 35116e.
  • One or more of bottom cross-members 35116a-351 16f may be a stamped sheet of metal.
  • bottom crossmember 351 16a is made of a sheet of metal.
  • Upper tubes 35104, 35106 are connected by upper cross-members 35118a and 35118b (best shown in Figure 38).
  • crossmember 351118a of frame 35012 is a tubular member or tube extending generally perpendicular to the longitudinal axis of the ATV
  • cross-member 35118b of frame 35012 has a slightly different configuration. More specifically, cross-member 35118a is a tubular member extending along a transverse axis (i.e., generally perpendicular to the longitudinal axis of the ATV) while cross-member 351 18b is made of a stamped sheet of metal.
  • cross-members 35118a-35118b can vary without departing from the scope of this embodiment, where some of all of them could all be made of tubular members or stamped sheets of metal, and could adopt different shapes or different angles relative to the longitudinal or transverse axis of the ATV 10.
  • the front upwardly extending tubes 35108 and 35112 are connected to one another via cross-members 35119a-35119c.
  • lower tubes 35100, 35102, upper tubes 35104, 35106, front and rear upwardly extending tubes 35108, 35110, 35112, 35114 and cross-members 35116a-351 16f, 351 18a-35118b and 35119a- 35119c define an engine compartment 35120 (see Figures 35-37) for receiving the engine (e.g., engine 14 of the ATV 10), as well as a portion of the front and/or rear transmissions (e.g., transmission 20, 26), as it will be described in greater detail below.
  • Left front tube 35117 has a top end 35121 connected to crossmember 35118a, at the junction of front upwardly extending left tube 35108, and a bottom end 35123 attached to a front end 35125 of left lower tube 35100.
  • a right-front tube 35127 extends downwardly from cross-member 35118a.
  • Right front tube 35127 has a top end 35129 connected to cross-member 35118a, at the junction of front upwardly extending right tube 35112, and a bottom end 35131 attached to a front end 35133 of right lower tube 35102.
  • the right upper tube 35106 extends from a right top proximal end portion through a middle portion to a righttop distal end portion.
  • the left uppertube 35104 extends from a left top proximal end portion through a middle portion to a left top distal end portion.
  • the left footrest subframe 35130 extends outwardly sidewardly from the left end portion of the front top cross-member 351 18a or from the left top distal end portion of the left upper tube and downwardly to a left bottom end portion.
  • the right upper tube 35106 is at a first distance di from the right bottom tube 35102 and the left upper tube 35104 is at a second distance d2 from the left lower tube 35100.
  • first and second distances di and d 2 are measured at corresponding left and right positions along the longitudinal axis.
  • the first distance di is greater than the second distance d 2 and the left and right lower tubes 35100, 35102 and the left and right upper tubes 35104, 35106 define therebetween the engine housing adapted to receive engines of different sizes while the space adapted to receive a component or components of the all-terrain vehicle is defined above the left upper tube 35104 and therebetween the left footrest subframe 35130 and the right upper tube 35106.
  • the first distance di may be between about 65 cm and about 45 cm and the second distance d 2 may be between about 60 cm and about 40 cm.
  • front wheels e.g., wheels 16a, 16b
  • front suspension e.g., front suspension 18
  • a left footrest subframe 35130 for supporting a footrest (e.g., footrest 32a).
  • a right footrest subframe 35132 for supporting a footrest (e.g., footrest 32b), which extends sidewardly from the right lower and upper tubes 35102, 35106.
  • Left and right footrest subframes 35130 and 35132 being similar to subframes 130 and 132 of frame 12, the description of subframes 130 and 132 is also applicable to subframes 35130 and 35132 respectively, with proper adaptations.
  • left and right subframes 35130, 35132 provide a structure or frame onto which can be mounted left and right footrests (e.g., left and right footrests 32a, 32b). Furthermore, as it will be appreciated, left and right footrest subframes 35130, 35132 contribute to the overall rigidity of the main frame 35012.
  • the rear fender portion 35158 comprises left and right lower tubes 35156, 35176, as well as, left and right upper tubes 35162, 35182.
  • the left and right upper tubes 35162, 35182 will sometimes be referred to as “longitudinal members” 35162, 35182 being understood that the terms “upper tubes” are used interchangeably with “longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
  • Left lower tube 35156 comprises a front end 35190 attached to the cross-member 35116f (see Figures 36 and 39), as well as a rear end 35192.
  • right lower tube 35176 comprises a front end 35194 attached to the cross-member 351 16f, and a rear end 35196 (see Figure 37).
  • the left and right lower tubes 35156, 35176 are substantially straight and converge toward one another, from the front ends 35190, 35194 to the rear ends 35192, 35196 thereof, while being substantially parallel to the ground when seen from the side (e.g. Figures 36 and 37) and configured to accommodate the rear drive train (e.g., drive train 200), as it will become apparent below.
  • the left and right lower tubes 35156, 35176 are also connected to one another by way of at least one cross-member 35204.
  • left upper tube 35162 of the rear fender portion 35158 comprises a front end 35206 and a rear end 35208, the front end 35206 being attached to the left upwardly extending tube 351 10.
  • right uppertube 35182 ofthe rear fender portion 35158 comprises a front end 35235 and a rear end 35212, the front end 35235 being attached to the rear right upwardly extending tube 35114.
  • the left and right upper tubes 35162, 35182 of the rear fender portion 35158 diverge away from one another, from their respective front ends 35206, 35235, toward their rear ends 35208, 35212.
  • the left and right upper tubes 35162, 35182 are also connected to one another by way of cross-members 35216a- 35216c, extending in intermediate locations between the front ends 35206, 35235 and the rear ends 35208, 35212 of the left and right upper tubes 35162, 35182.
  • left and right angular tubes 35151 , 35153 Extending between a midpoint on a cross-member 35216a-35216c between the left and right upper tubes 35162, 35182, and the left and right lower tubes 35156, 35176, respectively, are left and right angular tubes 35151 , 35153 ( Figure 36, 37 and 41).
  • Left angular tube 35151 comprises a top portion 35154 and a bottom portion 35134.
  • right angular tube 35153 comprises a top portion 35137 and a bottom portion 35138.
  • bottom portions 35134, 35138 of the left and right angular tubes 35151 , 35153 Extending at a bottom end ofthe bottom portions 35134, 35138 of the left and right angular tubes 35151 , 35153 is a lower cross-member 35202.
  • Bottom portions 35134, 35138 are substantially parallel, while top portions 35154, 35137 extend from the bottom portions to the midpoint on a cross-member 35216a-35216c, converging and connecting to the crossmember at an apex.
  • a hitch assembly as further described herein may be secured to the bottom portions.
  • Mounted to the rear fender portion 35158 is a rear rack 35159 similar to rear rack 10159 described above. The same numerals are used to denote similar features, or features performing a similar function in the rear rack 35159 of this embodiment as in rack 10159.
  • front bumper assembly 35013 is configured to be assembled to the main frame 35012 using threaded fasteners 35232a, 35232b and 35234a-35234d, which are also used to mount portions of the front suspension (e.g., front suspension 18) between the front bumper assembly 35013 and the main frame 35012, as it will become apparent below.
  • front bumper assembly 35013 comprises left and right curved tubes 35236, 35238, each tube having a top end 35240, 35242 and a lower end 35244, 35246.
  • the left and right front curved tubes 35236, 35238 are attached to one another by way of a top cross-member 35248 (shown in Figure 43).
  • a further cross-member 35249 may be disposed between left and right curved tubes.
  • Connecting the lower ends 35244, 35246 of the left and right curved tube 35236, 35238 is a mounting plate 35250, similar to mounting plate 250 of bumper assembly 13.
  • the front bumper assembly 35013 further comprises an intermediate cross-member 35254, extending between the left and right curved tube 35236, 35238, in an intermediate location between the top end 35240, 35242 and the lower end 35244, 35246 thereof, as well as a protective plate 35256 extending between the mounting plate 35250 and the intermediate cross-member 35254.
  • the top rack portion 1300 comprises a tube 1302 defining a periphery and having a front end 1304, a back end 1306 and left and right side ends 1308, 1335 which together define a space 1312 for receiving a storage compartment 1313 (shown in Figures 1 to 4).
  • left and right mounting tubes 351330 and 351332 extending from the left and right curved tubes 35236, 35238 towards the main frame 35012 are left and right mounting tubes 351330 and 351332, having one end connected to the left and right curved tubes, respectively, and each being provided with left and right securing brackets 35286, 35288 or other attachment means on the other end for securing to the main frame 35012.
  • Left and right connecting members 351328, 351336 connect the brackets on the left and right mounting tubes 351330 and 351332 to the peripheral tube 1302.
  • the securing brackets 35286, 35288 (shown in Figures 44 and 45) each comprise holes (not shown) for receiving therethrough threaded fasteners 35234a-35234d (shown in Figures 43 to 45) for securing the top end of the bumper assembly 35013 to left and right front tubes 35117, 35127 of the main frame 35012.
  • the fact that the front bumper assembly 13, 10013 or 35013 is removably attached to the main frame 12, 10012 or 35012, respectively, can be advantageous in a number of ways. For instance, if the bumper assembly 13, 10013 or 35013 becomes damaged because of an impact of the ATV 10 with an obstacle during its operation, the front bumper assembly 13, 10013 or 35013 can be replaced without the need of replacing the entirety of the main frame 12, 10012 or 35012. Furthermore, different front bumper assembly configurations can be used in conjunction with a same main frame 12, 10012 or 35012.
  • different front bumper assemblies 13, 10013 or 35013 can be used to meet different front rack configurations, or to mount a hitch, a plow or other types of tools commonly used in connection with ATVs such as ATV 10.
  • the seat 30 Mounted on the main frame 12, 10012 or 35012, on top of top longitudinal members or uppertubes 104, 106, 10104, 10106, 35104, 35106 and longitudinal members or tubes 162, 182, 10162, 10182, 35162, 35182 of the rear fender portion 158, 10158 or 35158 is the seat 30 (the seat 30 being shown in Figures 1 to 9).
  • the seat 30 can be mounted to the main frame 12, 10012 or 35012 using brackets or other types of intermediate structures, or it can be mounted directly to the main frame 12, 10012 or 35012.
  • fairings e.g. fairing 10014
  • FIG. 1 to 4 are fairings for protecting the operator and the internal components of the ATV 10 (shown in Figures 1 to 4).
  • the configuration of the main frames 12, 10012 or 35012 and bumper assemblies 13, 10013 or 35013 may prove advantageous in some instances.
  • the configuration of the main frames 12, 10012 or 35012 enables positioning the seat 30 such that the operator sits in a more forward and lower seating position without significantly altering the wheelbase, ground clearance and suspension travel of the vehicle.
  • an ATV 10 equipped with a main frame 12, 10012 or 35012 and having a wheelbase of 51 inches (129.5 cm), a front suspension travel of 9 inches (22.9 cm) a rear suspension travel of 8.8 inches (22.4 cm) and a ground clearance of 10.5 inches (26.7 cm), has a seat 30 having a front end at 27.36 inches (695 mm) behind the axle of the front wheels 16a, 16b and a rear end at 49.45 inches (1256 mm) behind the axle of the front wheels 16a, 16b, and a seating portion having a top surface in showroom configuration (/.e.
  • the foam uncompressed ranging from 24.84 inches (631 mm) above the lowest portion of the main frame 12, 10012 or 35012 (at the proximal to the front end of seat 30) to 25.55 inches (649 mm) above the lowest portion of the main frame 12, 10012 or 35012 (at the rear end of the seat), and a ground clearance (i.e., the distance between the ground and the lowest portion of the main frame 12) ranging from 8.75 inched to 9.25 inches (222.25 mm to 234.95 mm).
  • the comparable model year 2018 Can-AmTM Outlander 450 in this instance has a wheelbase of 51 inches (129.5 cm), a front suspension travel of 9 inches (22.9 cm) a rear suspension travel of 8.8 inches (22.4 cm), a ground clearance of 10.5 inches (26.7 cm) and a seat having a seating portion located about 3 inches higher above ground than seat 30 of ATV 10.
  • the general configuration of the main frames 12, 10012 or 35012 and bumper assembly provides other various advantages over prior art ATV frame configurations.
  • the configuration of the main frames 12, 10012 or 35012 and bumper assemblies 13, 10013 or 35013 enables using a variety of shock absorbers having different lengths, and facilitates the assembly of the ATV 10 on the assembly line.
  • Figures 47 to 58 show further features of main frame 35012 for the all-terrain vehicle 10, the frame 35012 extending along a longitudinal axis L1-L1 and comprising a front portion 1610, a middle portion 1620 and a rear portion 1700.
  • the front portion 1610 is configured to receive left and right front shock absorbers (not shown) and the rear portion 1700 is configured to receive left and right rear shock absorbers (not shown).
  • the middle portion 1620 comprises a left bottom longitudinal member or lower tube 35100 extending from a left bottom proximal end portion 35101a through a middle portion 35101 b to a left bottom distal end portion 35101c, a right bottom longitudinal member or lower tube 35102 extending from a right bottom proximal end portion 35103a through a middle portion 35103b to a right bottom distal end portion 35103c, a left upper tube 35104 extending from a left top proximal end portion 35105a through a middle portion 35105b to a left top distal end portion 35105c, and a right top longitudinal member or upper tube 35106 extending from a right top proximal end portion 35107a through a middle portion 35107b to a right top distal end portion 35107c.
  • One of the left and right top longitudinal member or upper tubes 35104, 35106 may be at a first distance di from the first left bottom longitudinal member or lower tube 35100 or the right bottom or lower tube 35102. As shown, the right top longitudinal member or upper tube 35106 is at the first distance di from the right bottom longitudinal member or lower tube 35102.
  • Another of the left and right top longitudinal member or upper tubes 35104, 35106 may be at a second distance d 2 from the left bottom longitudinal member or lower tube 35100 or the right bottom longitudinal member or lower tube 35102. As shown, the left top longitudinal member or upper tube 35104 is at the second distance d 2 from the left bottom longitudinal member or upper tube 35100.
  • first and second distances di, d 2 are measured at corresponding positions along the longitudinal axis L1-L1 (at corresponding left and right positions along the longitudinal axis L1-L1).
  • first distance di between the right top longitudinal member or upper tube 35106 and the right bottom longitudinal member or lowertube 35102 may be measured at a right position RP along the longitudinal axis L1-L1
  • second distance d 2 between the left top longitudinal member or upper tube 35104 and the left bottom longitudinal member or lowertube 35100 may be measured at a left position LP along the longitudinal axis L1-L1, the right position RP corresponding to the left position LP.
  • the left position LP may be at 30 cm from the left bottom proximal end portion 35101 a
  • the right position RP may be at a corresponding 30 cm from the right bottom proximal end portion 35103a.
  • the first distance di is greater than the second distance d 2 .
  • the first distances di may be between about 65 cm and about 45 cm and the second distance d 2 may be between about 60 cm and about 40 cm.
  • the first distances di may be between about 65 cm and about 45 cm and the second distance d 2 may be between about 60 cm and about 40 cm. More particularly, the first distance di may be between 62 cm and about 61 cm at the left proximal end portion, between about 59 cm and about 61 cm at the left middle portion, and between about 43 cm and about 45 cm at the left distal end portion and the second distance d 2 may be between about 62 cm and about 61 cm at the right proximal end portion, between about 53 cm to about 57 cm at the right middle portion, and between about 43 cm and about 45 cm at the right distal end portion.
  • first and second distances di, d 2 may be determined to provide the left and right bottom or lower tubes 35100, 35102 and left and right top or upper tubes 35104, 35106 that define therebetween the housing HO adapted to receive engines of different sizes while a suitable space S is adapted to receive a component of the all-terrain vehicle 10 is defined above the left top longitudinal member or upper tube 35104 and therebetween the left longitudinal member or tube 35130 and the right top longitudinal member or upper tube 35106.
  • the left and right bottom or lower tubes 35100, 35102 and the left and right top or upper tubes 35104, 35106 define therebetween an engine compartment (or engine housing) HO adapted to receive engines having different sizes, such as engine E1 having a first size and an airbox 11500’ (see Figure 52A) and an engine E2 having a second size with an airbox 11500” (see Figure 52B), the second size being larger than the first size.
  • the airbox 1 1500’, 1 1500” may be adapted to the size of the engines E1 , E2 More specifically, and as best seen in Figures 55 and 56, the engine compartment HO is adapted to receive the first engine E1 having the first size.
  • the first engine E1 may comprise one cylinder.
  • the monocylinder engine E1 may comprise the cylinder head extending towards the rear end of the all-terrain vehicle 10 (also seen in Figures 55 to 58).
  • the engine E1 is a RotaxTM 427cc liquid cooled single cylinder.
  • the engine E1 is mounted in the engine compartment HO, where the cylinder head extends towards the rear end of the ATV 10 (see Figures 55 to 58).
  • the engine compartment HO is also adapted to receive the second engine E2 having the second size.
  • the second engine E2 may be a two-cylinder engine.
  • the first and second engines E1 , E2 may be two-stroke engines, four-stroke engines, diesel engines or an electric motors. Further, each of the engines E1 or E2 may be an in-line, three-cylinder, four-stroke internal combustion engine or a V-twin engine. It is also contemplated that other types of internal combustion engines could be used, such as a two-stroke internal combustion engine.
  • the first and second engines may comprise two, four or six poles.
  • the electric motor (not shown) may have a power of between about 1 to about 300 HP or between about 0.7 to about 220 kW.
  • a space S is defined above the other of the left and right top longitudinal member or upper tube 35104, 35106 being at the second distance d 2 .
  • the space S is defined above the left top upper tube 35104 that is at the second distance d 2 .
  • the space S is defined between the left top longitudinal member or upper tube 35104 and the right top longitudinal member or upper tube 35106.
  • the space S is adapted to receive a component or components of the ATV, where the components may be airboxes 11500’, 11500”. It is understood that other components such as a power steering assembly 920’, steering cables 11600a, 11600b, an air filter 11700, a storage compartment (not shown) or a battery (not shown) may alternatively or concurrently be received in the space S.
  • a power steering assembly 920’ steering cables 11600a, 11600b, an air filter 11700, a storage compartment (not shown) or a battery (not shown) may alternatively or concurrently be received in the space S.
  • the middle portion 1620 may comprise a first top cross-member 351 18a extending between the left top proximal end portion 35105a of the left top longitudinal member 35104 and the right top proximal end portion 35107a of the right top longitudinal member 35106.
  • the front top cross-member 35118a comprises left and right end portions 1911 , 1912.
  • the middle portion 1620 may also comprise a left longitudinal member 35130 extending outwardly sidewardly from the left end portion 1911 of the front top crossmember 351 18a or from the left top proximal end portion 35105a of the left top longitudinal member 35104 and downwardly to a rear left bottom end 1881 .
  • the space S is defined between the left longitudinal member 35130 and the left top longitudinal member 35104.
  • the middle portion 1620 may comprise a right longitudinal member 35132 extending outwardly sidewardly from the right proximal end portion 1912 of the front top cross-member 351 18a or from the right top proximal end portion 35107a of the right top longitudinal member 35106 and downwardly to a rear right bottom end 1891.
  • the middle portion 1620 may also comprise a front upwardly extending left tube 35108 extending upwardly from the left bottom longitudinal member 35100 up to the first top cross-member 35118a and a front upwardly extending right tube 35112 extending upwardly from the right bottom longitudinal member 35102 up to the first top crossmember 35118a.
  • the middle portion 1620 of the frame 35012 may comprise a first lower cross-member or a cross-member bracket 35135 connecting the left bottom longitudinal member 35100 and the right bottom longitudinal member 35102 at the left and right bottom proximal ends 35101 a, 35103a and a second lower cross-member 35119a comprising left 1931 and right 1932 end portions, and extending between the left bottom longitudinal member 35100 and the right bottom longitudinal member 35102 at the middle portion 35101 b, 35103b of first left and right bottom longitudinal members 35100, 35102.
  • the left end portion 1931 of the second lower cross-member 35119a connects the front upwardly extending left tube 35108 extending upwardly and the left bottom longitudinal member 35100 and the right end portion 1932 of the second lower cross-member 35119a connects the front upwardly extending right tube 35112 extending upwardly and the right bottom longitudinal member 35102.
  • the middle portion 1620 may also comprise a second top cross-member 35118b connecting the left and right top longitudinal members 35104, 35106 at respective left and right middle portions 35105b, 35107b of the left and right top longitudinal member or upper tubes 35104, 35106.
  • the space S may be defined above the second top crossmember 35118b;
  • the middle portion 1620 may further comprise a rear left upwardly extending tube 35110 extending upwardly from the left bottom distal end portion 35101 c of the left bottom longitudinal member or lower tube 35100 to the left top distal end portion 35105c of the left top longitudinal member 35104 and a rear right upwardly extending tube 35114 extending upwardly from the right bottom distal end portion 35103c of the right bottom longitudinal member 35102 to the right distal end portion 35107c of the right top longitudinal member 35106.
  • the middle portion 1620 of the frame comprises a rear left engine mounting bracket 1810a, 1810a’, a front left engine mounting bracket 1820, 1820’, a rear right engine mounting bracket 1810b, 1810b’ and a front right engine mounting bracket 1822, 1822’.
  • the rear and front left engine mounting brackets 1810a, 1810a’; 1820, 1820’ and the rear and front right engine mounting brackets 1810b, 1810b’; 1822, 1822’ comprise rear and front left connectors (not shown) and rear and front right connectors (not shown) for mounting one of the first and second engines E1 , E2 to the middle portion 1620 in the engine compartment HO.
  • the front left engine mounting brackets 1820, 1820’ are removably mounted to the middle portion 35101 b of the left bottom longitudinal member 35100 and/or a bottom end of the front upwardly extending left tube 35108.
  • the front right engine mounting brackets 1822, 1822’ are removably mounted to the middle portion 35103b of the right bottom longitudinal member 35102 and/or a bottom end of the front upwardly extending right tube 351 12.
  • the rear left engine mounting brackets 1810a, 1810a’ are removably mounted adjacent the left bottom longitudinal member 35100 and the rear right engine mounting brackets 1810b, 1810b’ are removably mounted adjacent the right bottom longitudinal member 35102.
  • each of the first and second engine E1 , E2 comprises a first left and right bottom connectors and a rear bottom connector for allowing respective mounting of the first engine E1 or the second engine E2.
  • first left bottom engine mounting bracket 1820, the first right bottom engine mounting bracket 1822, and the rear bottom engine mounting bracket 1810 may be adapted to the size of the engine and the type of left and right bottom connectors, and the rear bottom connector of the engine.
  • bottom engine mounting bracket 1820’, the first right bottom engine mounting bracket 1822’, and the rear bottom engine mounting bracket 1810’, or the rear bottom engine mounted brackets 1810a’, 181 Ob’ allow for mounting the second engine E2 being of larger size than the first engine E1 .
  • front suspension 18 is a double A-arm suspension (also known as a “double-wishbone suspension”) comprising left and right front suspension subassemblies 292, 294.
  • the left and right front suspension subassemblies 292, 294 being mirror images of one another, only left front suspension subassembly 292 will be described. It will be understood that a similar description also applies to right front suspension subassembly 294, with proper adaptations.
  • Left front suspension subassembly 292 comprises a lower A-arm 296, and upper A-arm 298, a knuckle 300, as well as a shock absorber 301 including a dampener 302 and a coil spring 304.
  • the lower A-arm 296 comprises a first end 306 with two mounting points 308a, 308b for mounting the lower A-arm 296 to the main frame 12, and a second end 310 operatively connected to the knuckle 300.
  • the upper A-arm 298 comprises a first end 312 with two mounting points 314a, 314b for mounting the upper A-arm 298 to the main frame 12, and a second end 316 operatively connected to the knuckle 300.
  • the knuckle 300 extends between the two second ends 310, 316 of the lower and upper A-arms 296, 298, respectively and allows for securing the left wheel 16a to the front suspension 18 and permits vertical travel movement of the front suspension 18.
  • the dampener 302 comprises a lower end 320 attached to the upper A-arm 298, and an upper end 322 for securing the dampener 302 to the main frame 12 of the ATV 10.
  • Concentrically mounted on the dampener 302 is the coil spring 304. Together, the dampener 302 and coil spring 304 mounted to the upper A-arm 298 and to the main frame 12 contribute to control vertical travel movement of the front suspension
  • the configuration of the left and right front suspension subassemblies 292, 294 can be adjusted so as to control or define the various parameters of the front suspension 18, such as, for instance, the travel, the camber angle, the caster angle, the toe pattern, the roll center height, the scrub radius, bump steer and the like.
  • bushings and/or bearings are provided at the first and second ends 306, 312, 310 and 316 of the lower and upper A-arms 296, 298, as well as at the lower and upper ends 320, 322 of the dampener 302, to allow proper movement of the front suspension 18 during the operation of the ATV 10.
  • the front bumper assembly 13 and the front suspension 18 the assembly of these three components will now be described. It will be appreciated that, prior to assembling these three components together, other components of the ATV can be pre-assembled to one of these components. Furthermore, the front bumper assembly 13 and/or the front suspension 18 can be assembled together prior to being assembled with the main frame 12, and that the assembly of the main frame 12, the front bumper assembly 13 and/or the front suspension 18 together need not precede other assembly steps required for the assembly of the ATV.
  • the main frame 12 is first provided.
  • a first set of threaded fasteners 234a, 234b (in this case, a pair of bolts, as shown in Figures 18,
  • a second set of threaded fasteners 326a, 326b (in this case, also a pair of bolts, shown in Figures 18 and 21) are positioned in holes (not shown) of cross-member 1 19b.
  • a third set of threaded fasteners 324a, 324b (in this case, a pair of bolts, shown in Figures 18 and 22) are positioned in holes (not shown) of cross-member 116b of the main frame.
  • a fourth set of threaded fasteners 328a, 328b are positioned in cross-member 147 extending between left and right front tubes 117, 127 (fasteners 328a and 328 also being shown in Figures 19 and 20, respectively).
  • a fifth set of fasteners 232a, 232b are positioned in holes 141 a, 141 b of cross-member bracket 135 of the main frame 12. With the fasteners in position in their respective holes, the front suspension 18 is now mounted to the main frame 12.
  • the rear portion of the second end 316 of the upper A-arm 298 is attached to cross-member 119b, while the front portion of the second end 316 ofthe upper A-arm 298 is secured to the cross-member 147 extending between left and right front tubes 117, 127.
  • the rear portion of the second end 310 of the lower A-arm 296 is attached to the cross-member 1 18a of the main frame 12, while the front portion of the second end 310 is attached to the crossmember bracket 135.
  • the lower end 320 of the dampener 302 onto which is mounted the coil spring 304 is then attached to the upper A-arm 298 while the top end 322 is mounted to the fasteners 234a, 234b extending in the holes of the cross-member 1 18a.
  • the various components can be maintained into position on the various threaded fasteners using bolts secured onto the various threaded fasteners 232a, 232b, 234a, 234b, 324a, 324b, 326a, 326b, 328a and 328b. Alternatively, they can be maintained into position using clamps or the like until all bolts are secured. With these components in position, the front bumper assembly 13 can then be assembled to the main frame 12.
  • the first set of fasteners 234a, 234b are engaged in the holes (not shown) defined in the brackets 286, 288 of the upper cross-member 274 of the bumper assembly 13 while fasteners 232a, 232b are engaged in holes 252a, 252b of the lower mounting plate 250 of the bumper assembly 13 (see Figure 17).
  • the front bumper assembly 13 is then securely attached to the main frame 12, using appropriate torqueing tools.
  • the top end 322 ofthe dampener 302 is thus sandwiched between the crossmember 274 of the bumper assembly 13 and the cross-member 118a of the main frame 12.
  • the front portions of the lower A-arm 296 are sandwiched between the lower mounting plate 250 of the bumper assembly 13 and the cross-member bracket 135 of the main frame 12.
  • suspension 18 would be mounted similarly to frame 10012 and front bumper assembly 10013 using fastener 10234a, 10234b, as well as fasteners 10232a, 10232b.
  • fastener 10234a, 10234b as well as fasteners 10232a, 10232b.
  • the description of the attachment of front suspension 18 to frame 12 and bumper assembly 13 is also application to the attachment of the suspension 18 to the frame 10012 and front bumper assembly 10013, with proper adaptations.
  • Suspension 75100 may be integrated to an ATV 10 comprising a main frame as described herein and illustrated in Figures 35-46.
  • the suspension comprises left and right lower A-arms 70102, 75112.
  • Each extremity of the lower A-arms defines a circular cavity 75120a-75120d extending along a longitudinal axis, configured to receive bushings 75121 a-75121d.
  • a front bracket 75130 is configured to extend between the front extremities of A-arms 75102, 75112, comprising holes configured to abut the circular cavities 75120a-75120-d and bushings 75121 a-75121d.
  • Fasteners configured to fasten the front extremities of A-arms 75102-75112, bushings 75121 a, 75121 c and front bracket 75130 may comprise bolts 75122a, 75122b and nuts 75123a, 75123b.
  • the fasteners may be further configured to fasten additional elements to those already described, for instance at least one component of a main frame 12, 10012 or 35012.
  • front bracket 75130 is cross-member bracket 35135 and is further configured to receive threaded fasteners 35232a, 35232b for attaching front bumper assembly 35013 to main frame 35012. Accordingly, the cross-member bracket links front bumper assembly 35013 and suspension assembly 75100 to front tubes 35117 and 35227.
  • Suspension assembly 75100 further comprises means to attach the rear extremities of lower A-arms 75102, 75112 to a frame such as main frame 12, 10012 or 35012.
  • the means may comprise fasteners, comprising bolts 75124a-75124b, nuts 75125a-75125b and bracket 75126.
  • the fasteners may be configured to attach rear extremities of the A-arms 75102, 751 12, rear bracket 75126, and bushings 75121 b, 75121d to a member 75127, the member 75127 forming part of a main frame 12, 10012 or 35012.
  • the member 75127 is cross-member 351 19a.
  • a small tubular frame member in the form of a sleeve is secured into the holes ofthe various elements of the main frame 12 (e.g. holes 141 a, 141 b of cross-member bracket 135), as described in US Patent No. 9,815,145 issued on November 14, 2017, the entirety of which is incorporated herein by reference.
  • the various tubular members of the main frame 12, main frame 10012, main frame 35012, front bumper assembly 13, 10013 or 35013 and/or rear suspension 700 are secured or attached to one another using the method described in US Patent No. 9,815,145 issued on November 14, 2017, the entirety of which is incorporated herein by reference.
  • other methods for assembly the main frame 12, main frame 10012, main frame 35012, front bumper assembly 13, 10013 or 35013, the rear suspension assembly 700 and/or other components of the ATV 10 are also possible.
  • the rear suspension 400 is somewhat of a hybrid between an independent suspension and a classical swing arm suspension.
  • the rear suspension 400 makes use of the torsional characteristics of a specifically designed main swing arm 402 to allow securing of the rear suspension 400 to the main frame 12 of the ATV 10, as well as strategically positioned shock absorbers 41 1 , 413 comprising air/oil dampeners 412, 414 and coil springs 482, 484 (see Figures 71 to 73).
  • the rear suspension 400 comprises the main swing arm 402 having a front end 404 pivotally and/or articulably attached to the main frame 12, 10012 or 35012 of the ATV 10 via brackets 406, 408 (attached to the left and right lower tubes 100, 102 of the main frame 12) or 10406, 10408 (attached to the left and right lower tubes 10100, 10102 of the main frame 10012) and a rear end 410, as well as a pair of shock absorbers 411 , 413 extending between the rear end 410 of the swing arm 402 and the main frame 12 of the ATV 10, as described in greater detail below.
  • the main swing arm 402 comprises left and right portions 416, 418 attached to one another via a rear differential 420.
  • the left and right swing arm portions 416, 418 being essentially mirror images from one another, only left swing arm portion 416 will be described.
  • left swing arm portion 416 comprises a front portion 421 extending from the front end 404 to an intermediate location 422, and a generally T- shaped rear portion 426 extending from the intermediate location 422 to a rear end 424, at which rear end 424 it is attached or secured to a left sleeve portion 428.
  • the rear end 424 is welded to the left sleeve portion 428, which left sleeve portion 428 is adapted to rotatably receive a left half-shaft 430 therein.
  • the front portion 421 comprises a generally cylindrical tube 437 (/.e. a tube having a generally circular cross-section) extending from the front end 404 to the intermediate location 422.
  • a cylindrical cavity or recess 435 Provided at the front end 404 of the front portion 421 is a cylindrical cavity or recess 435 extending transverse to the longitudinal axis of the cylindrical tube 437.
  • the recess or cavity 435 is configured for receiving a bushing (not shown), for securing the left portion 416 to the bracket 406 of the lower left tube 100 of main frame 12 (shown in Figure 69).
  • the bushing (not shown) allows the left portion 416 to pivot about the pivot axis P-P (see Figure 69), as well as torsion movement L T -L T of left portion 416 of the swing arm relative to its attachment point (/.e. bracket 406) on the main frame 12, without compromising the pivoting movement about axis P-P.
  • the front and rear portions 421 , 426 are welded together. While in the illustrated embodiment the left portion 416 of the swing arm 402 is made of two separate components welded together (/.e.
  • the person skilled in the art will appreciate that it could be manufactured as a single piece, as it will become apparent below, with reference to Figures 78 to 84.
  • the rear portion 426 is welded to the left sleeve 428, the rear portion 426 could be secured to the left sleeve 428 differently, for instance using nuts, bolts, brackets, collars or any other type of suitable fastening means.
  • the rear portion 426 has a generally oblong cross-section.
  • the rear portion 426 is sized, shaped and made of a material allowing a limited torsion of the rear portion 426 about a longitudinal axis L T -L T (see axis L T -L T on Figure 69).
  • the torsional properties of the rear portion 426 allow the main swing arm 402 to twist along a longitudinal axis, therefore providing further degrees of freedom to the rear suspension 400 than conventional swing arms.
  • the left swing arm portion 416 is made of StrenxTM 700 structural steel having a 0.0551 inch (1.4 mm) thickness.
  • the left sleeve 428 comprises a wheel end 432 (/.e. the end shown on the left in Figure 70) and a differential end 434 (/.e. the end shown on the right in Figure 70).
  • the sleeve 428 is provided with a counterbored flange 436 configured for receiving therein a wheel bearing 438, and comprising a plurality of holes for receiving a corresponding plurality of threaded fasteners 440a-440d (in Figure 70, only fasteners 440a and 440b are shown) for maintaining the wheel bearing 438 in the counterbored flange 436 and the left half shaft 430 attached thereto, as it will become apparent below.
  • the sleeve 428 is provided with a radially extending flange 442 in which are defined a plurality of holes 443a-443d (in Figure 70, only holes 443a and 443b are shown).
  • the holes 443a-443d defined in flange 442 are sized and positioned for receiving a plurality of fasteners 444a-444d therethrough, for securing the left portion 416 of the swing arm 402, the differential 420 and the right portion 418 of the swing arm 402 together.
  • the differential 420 comprises a generally cylindrical casing 450 for housing the gears of the differential (not shown), the casing 450 having a generally circular left wall 452, a generally circular right wall 454 and a curved wall 456 extending between the left and right walls 452, 454, respectively.
  • the curved wall 456, about the periphery of the differential 420 are a plurality of holes 457a-457d (in Figure 70, only holes 457a and 457b are shown) for receiving the corresponding plurality of threaded fasteners 444a- 444d.
  • the casing 450 of the differential 420 thus plays a structural role in the main swing arm 402.
  • the casing 450 of the differential is sized and shaped so as to resist the various forces encountered by the rear transmission during the operation of the ATV 10.
  • the casing of the differential is made of aluminum, but it is contemplated that it could be made of any other suitable material.
  • the main swing arm 402 further comprises a hitch 460.
  • the hitch 460 comprises a pair of spaced-apart plate members 462, 464, each plate member 462, 462 having a circular portion (not shown) generally corresponding to the circular walls 452, 454 of the differential casing 450, and a tapering rear portion 466, 468.
  • each of the left and right plate members 462, 464 is a plurality holes (not shown), distributed to align with corresponding holes 443a-443d of the right and left flanges 442 of the left and right portions 416, 418 of the main swing arm 402, respectively, as well as with the holes 457a-457d defined in the curved wall 456 of the differential housing or casing 450.
  • Extending between the tapering portions 466, 468 of the left and right plate members 462, 464 is a cross-plate 470, configured for receiving a tow ball 472 or another type of attaching device for attaching a trailer to the ATV 10.
  • the hitch 460 could alternatively be used to attach a winch or another type of attachment commonly used on ATVs.
  • the hitch 460 becomes part of the main swing arm 402 by attaching the circular portions (not shown) of the left and right plate 462, 464 on each side of the differential casing 450. More specifically, the circular portion (not shown) of the left plate 462 is received between the right flange 442 of the left portion 416 and the left circular wall 452 of the differential casing 450. Likewise, the circular portion (not shown) of the right plate member 464 is received between the right circular wall 454 of the casing 450 and the left flange 442 of the right portion 418 of the main swing arm 402.
  • the hitch 460 is manufactured as a part that is distinct from the differential 420, it will be understood that other configurations are possible.
  • the hitch 460 could be integrally formed with the casing 450 of the differential 420.
  • the casing 450 of the differential 420 is a discrete component, it will be understood that other configurations are possible.
  • the differential 420 could form an integral structure with sleeves 428 of the left and right portions 416, 418.
  • the rear differential 420 is structural and is used to connect the left and right rear portions 416, 418, the person skilled in the art will appreciate that the rear suspension configuration could be used with any other type of transmissions, including more classical rear axles.
  • the left rear dampener 412 comprises a lower end 486 attached to a bracket 488 on the left swing arm portion 416, and an upper end 490 mounted to a bracket 492 found at the junction of rear, left upwardly extending tube 110 of the main frame 12 and upper left tube 162 of the rear fender portion 158 of the main frame 12 (shown in Figure 66).
  • the right rear dampener 414 comprises a lower end 494 attached to a bracket 496 of the right swing arm portion 418 (shown in Figure 71), and an upper end 498 mounted to a bracket 500 found at the junction of rear, right upwardly extending tube 114 of the main frame 12 and right upper tube 182 of the rear fender portion 158 of the main frame 12 (shown in Figure 67).
  • the left and right shock absorbers 41 1 , 413 in the showroom state define an angle 0i ranging from about 25 degrees to about 35 degrees relative to a vertical plan extending along the longitudinal axis of the ATV and an angle 0 2 ranging from about 40 degrees to about 50 degrees relative to a vertical plan extending perpendicular to the longitudinal axis of the ATV 10.
  • the left and right shock absorbers 411 , 413 in the showroom state define an angle 01 of 30.591 degrees and an angle 0 2 of 45.466 degrees.
  • the left and right portions 416, 418 of the main swing arm 402 are positioned on the exterior sides of the left and right lower tube members 100, 102 of the main frame 12, as well as on the exterior sides of the lower tubes 156, 176 of the fender portion 158 ofthe main frame 12. Furthermore, the tapering profile of the rear portions 426 of the left and right portions 416, 418 ofthe swing arm 402 are parallel to, but spaced apart from, the left and right lower tubes 100, 102 of the main frame 12, and the lower tubes 156, 176 of the fender portion 158 of the main frame 12.
  • the main swing arm 402 is free to pivot or travel upwardly and downwardly relative to the main frame 12, between a showroom state (shown in Figures 66 and 68) and bump state (shown in Figures 74 to 77). Furthermore, the space separating the left and right portions 416, 418 of the main swing arm 402, being wider than the space found between frame members of typical prior art swing arms, contribute to increase the torsional movement of the main swing arm 402 about the longitudinal axis (shown in Figure 68).
  • Rear suspension comprises ta main swing arm 402 having a front end 404 pivotally and/or articulably attached to the main frame 10012 of the ATV 10 (or frame 12) via brackets 10406, 10408 (attached to the left and right lower tubes 10100, 10102 of the main frame 10012) and a rear end 10410, as well as a pair of shock absorbers 10411 , 10413 extending between the rear end 10410 of the swing arm 10402 and the main frame 10012 of the ATV 10, as described in greater detail below.
  • the main swing arm 10402 comprises left and right portions 10416, 10418 attached to one another via a rear differential 10420.
  • the left and right swing arm portions 10416, 10418 being essentially mirror images from one another, only left swing arm portion 10416 will be described.
  • the person skilled in the art will appreciate that the same description also applies to right swing arm portion 10418, with proper adaptation.
  • left swing arm portion 10416 comprises a front portion 10421 extending from the front end 10404 to an intermediate location 10422, and a generally T-shaped rear portion 10426 extending from the intermediate location 10422 to a rear end 10424, at which rear end 10424 it is attached or secured to a left sleeve portion 10428.
  • the rear end 10424 is welded to the left sleeve portion 10428, which left sleeve portion 10428 is adapted to rotatably receive a left half-shaft 10430 therein.
  • front portion 10421 and rear portion 10426 of rear suspension 10400 are made of a single piece.
  • the other elements of the rear suspension 10400 being essentially identical to those of rear suspension 400, it will be understood that the description of those elements in connection with rear suspension 400 is also applicable to rear suspension 10400, with proper adaptation.
  • the rear portion 10426 having a generally oblong crosssection, and being sized, shaped and made of a material allowing a limited torsion of the rear portion 10426 about a longitudinal axis LT -LT (see axis L T -L T on Figure 80), as well as the gradually tapering front portion 10421 , provides the rear portion 10426 with torsional properties. Together with bushings at the front end 10404, the torsional properties of the rear portion 10426 allow the main swing arm 10402 to twist along a longitudinal axis, therefore providing further degrees of freedom to the rear suspension 10400 than conventional swing arms.
  • the left swing arm portion 10416 is made of StrenxTM 700 structural steel having a 0.0551 inch (1 .4 mm) thickness.
  • the rear drive train 200 comprises left and right drive half shafts 430 and 530.
  • the left and right drive half shafts 430, 530 being similar, only left half shaft 430 will be described. It will be appreciated that a similar description also applies to right half shaft 530, with proper adaptations.
  • Left half shaft 430 is sized and shaped to be received in left sleeve 428 of the main swing arm 402, the left half shaft 430 having a left end 532 to which is mounted a hub 534 and a splined right end 536 receivable in the differential 420 and collaborating with a corresponding splined bore (not shown) for allowing motion of the left rear wheel 22a.
  • the diameter of the half shaft 430 is slightly wider than the inner diameter of the inner race of the bearing 438, such that the bearing 438 can be secured to the left end 532 of the half shaft 430 by frictional engagement, and prevent unwanted movement of the bearing 438 relative to the half shaft 430.
  • the bearing 438 is mounted to the left end 532 of the half shaft 430 using a hydraulic press, by heat treating the bearing 438 prior to its assembly onto the half shaft 430, or using a combination of both. Once the bearing 438 is secured to the left end 532 of the half shaft 430, the left half shaft 430 is slid into the left sleeve 428, until the splined end 536 engages the corresponding splined bore (not shown) of the differential 420.
  • the bearing 438 of the left half shaft 430 is received in the counterbored flange 436 extending at the left end 432 of the sleeve 428, the left side 538 of the bearing 438 being close to be in alignment with the counterbored flange 436.
  • bolts (not shown in Figure 70) are secured onto threaded fasteners 540a-540d, the bolts engaging the outer race of the bearing 438.
  • the bolts are further screwed on the threaded fastener 540a-540d, they force the bearing 438 into the counterbored flange 436 until the left half shaft 430 is properly positioned into sleeve 428.
  • the inner race of the bearing is free to rotate, thereby allowing rotation of the left rear wheel 22a.
  • the hub 534 provided at the left end 532 of the left half shaft 430 comprises a central portion 542 and a plurality of projections 544a-544d extending radially from the central portion 542.
  • Each of the radial projections 544a-544d comprises a hole 546a-546d for receiving therein a threaded fastener 548a- 548d (shown in Figure 73), the threaded fasteners 548a-548d of the plurality of projections 544a-544d being used to secure the left rear wheel 22a to the hub 534.
  • the hub 534 comprises four (4) radial projections distributed symmetrically about the central portion 554, such that a space 550a-550d is defined between each pair of adjacent projections e.g. between projections 544a and 544b).
  • the rim 552 of the rear wheel 22a is provided with corresponding spaces 554a- 554d between each pair of adjacent spokes 556a-556d.
  • the spaces between the pair of adjacent projections e.g. space 550a
  • the spaces between the spokes of the wheel e.g.
  • the configuration of the illustrated embodiment allows removing the left half shaft 430 from the left sleeve 428 without having to remove the left rear wheel 22a form the hub 534, and, conversely to assemble the left half shaft 430 into the left sleeve 428 while the left rear wheel 22a is mounted to the hub 534.
  • This can prove to be advantageous, for instance on the assembly line of the ATV.
  • such a configuration contributes to avoiding the use of joints, which may be more prone to wear and tear.
  • the rear drive train 10200 comprises left and right drive half shafts 10430 and 10530, in accordance with an alternate embodiment.
  • the left and right drive half shafts 10430, 10530 being similar, only left half shaft 10430 will be described. It will be appreciated that a similar description also applies to right half shaft 10530, with proper adaptations.
  • Left half shaft 10430 is sized and shaped to be received in left sleeve 10428 of the main swing arm 10402, the left half shaft 10430 having a splined left end 10532 comprising a threaded portion 10533 to which can be mounted a hub 10534 and a splined right end 10536 receivable in the differential 10420 and collaborating with a corresponding splined bore (not shown) for allowing motion of the left rear wheel (e.g., rear wheel 22a).
  • left rear wheel e.g., rear wheel 22a
  • the diameter of the half shaft 10430 is slightly smaller that the inner diameter of the inner race of the bearing 10438, such that the bearing 10438 can be mounted about the left end 10532 of the half shaft 10430, as it will become apparent below.
  • the splined right end 10536 is engaged into the sleeve 10428
  • the left half shaft 10430 is slid into the left sleeve 10428, until the splined end 10536 engages the corresponding splined bore (not shown) of the differential 10420.
  • the bearing 10438 is then mounted to the left end 10532 of the half shaft and slid until it is received into a counterbored flange 10436 of the sleeve 10428.
  • a C-clip 10437 is positioned in the counterbored flange 10436 to secure the bearing 10438 in position, thereby preventing the half shaft 10430 to move out from its operating position.
  • the hub 10534 comprising a splined hole (not shown) is engaged onto the left end 10532 of the half shaft 10530, and a bolt 10535 is secured onto threaded 10533 portion to secure the hub 10534 to the left end 10532 of the half shaft 10430.
  • main swing arms 402 and 10402 could be used with any one of rear drive train 200 or 10200, or with other drive train configurations, without departing from the scope of the invention.
  • the gas tank 201 of the ATV 10 is adapted to be mounted to the rear fender portion 158 of the main frame 12.
  • the gas tank 201 is sized and shaped for receiving a suitable volume of gas (e.g. 5.4 gal. or 20.5 litres), and yet provide the rear suspension 400 with sufficient clearance for the main swing arm 402 to move between the fully extended position and the full-bump position.
  • the gas tank 201 has a generally bean shape when seen from either the left side or the right side (see Figures 85 and 91), and a generally L-shape when seen from the front or from the back (see Figures 86 and 87). More specifically, and as best shown in Figures 86 and 87 the gas tank 201 has a wider upper portion 600 which is adjacent to the right upper tube 182 of the rear fender portion 158 when the gas tank 201 is assembled to the main frame 12 (see Figure 77), and a lower, narrower portion 602. With reference to Figure 86, in the illustrated embodiment, the gas tank 201 includes a top wall 604 having a generally straight, forward portion 606, and a rear, inclined portion 608.
  • a front wall 610 Extending downwardly from the forward portion 606, at the front end of the gas tank 201 , is a front wall 610. At the rear end of the rear inclined portion 608, is a downwardly extending back wall 612. To define the lower, narrower portion 602 of the gas tank 201 , a bottom wall 614 extends between the front wall 610 and the back wall 612, the bottom wall 614 comprising first, second, third and fourth portions 616, 618, 620 and 622, respectively, extending sequentially from the front end to the rear end. Furthermore, and as best shown in Figures 86 and 87 the lower narrower portion 602 includes a pair of left and right side walls 624, 626, respectively.
  • the gas tank 201 also includes a neck 634 (shown in Figures 85 and 86), a fuel line, a fuel meter/fuel pump, a strainer and other parts typically required for operatively connecting the gas tank 201 to the engine 14.
  • the recess 632 defined by the bottom wall 630 of the wider portion 600 and the left wall 624 of the narrower portion 602 is configured for receiving the differential 420, when the rear suspension 400 is in a fullbump position, while first, second, third portions 616, 618 and 620 of the bottom wall 614 of the narrower portion 602 are configured to accommodate the presence of the rear portion 426 and sleeve 428 of the right arm portion 418 of the main swing arm 402.
  • the gas tank 201 is mounted to the cross-members 216a (cross-member 216a being shown in Figure 13) and 202 of the rear fender portion 158 via a front tab 654 extending frontwardly from front wall 610 of gas tank 201 and a rear tab 656 extending rearwardly from back wall 612, using threaded fasteners 658 and 660, and via side tab 662 extending sidewardly from side wall 626 and attached to tube member 228 using threaded fastener 664 (see Figures 74, 76 and 77).
  • the exhaust system 650 is configured for allowing full travel of the main swing arm 402 between the showroom position and the fullbump position.
  • the exhaust system 650 comprises a muffler 652 mounted to the rear fender portion 158 of the main frame 12, generally under the left upper tube 162 of the fender portion 158.
  • the muffler 652 is sized, shaped and positioned on the rear fender portion 158 such that, together with the configuration of the gas tank 201 , a space or recess is provided for accommodating the differential 420 when the rear suspension 400 is in full bump position.
  • the position of the gas tank 201 and of the muffler 652 contribute to balance the fore/aft weight of the ATV 10, since the configuration of the frame assembly (/.e. main frame 12, front bumper assembly 13 and rear suspension 400) tends to move the rider in a position that is more forward than on conventional ATVs and the displacement of the rider’s weight towards the front end of the ATV is advantageously counterbalanced by moving the gas tank 201 further rearward of the vehicle, as illustrated in this embodiment.
  • the cross-member 202 of the rear fender portion 158 acts as a stopper for preventing unwanted impact of a trailer portion (not shown) attached to the trailer hitch 460, when the main swing arm 402 moves from the showroom position to the bump position (the bump position being shown in Figure 77).
  • the gas tank 201 is prone to impact with the portion of the trailer (not shown) attached to the trailer hitch 460 as the rear suspension 400 is in a full-bump state and the ATV 10 is making a right turn.
  • the subframe 222 is provided to protect the gas tank 201 in such operating condition.
  • the tubes 224, 228, 230 and 231 of the subframe 222 are configured to substantially match the contour of the bottom wall 614 of the lower portion 602 of the gas tank 201 and to prevent a trailer hitch or attachment from contact with the gas tank 201 during the operation of the ATV 10.
  • gas tank 201 is located on the right side of the rear fender portion 158 and the muffler 652 is located on the left side, it will be understood that this configuration could be mirrored and the gas tank 201 be located on the left side and the muffler on the right side of the fender portion 158. Furthermore, it will be appreciated that alternate muffler and/or gas tank configurations are also possible without departing from the scope of the embodiment.
  • the gas tank 10201 of the ATV 10 is adapted to be mounted to the rear fender portion 10158 of the main frame 10012.
  • the gas tank 201 is sized and shaped for receiving a suitable volume of gas (e.g. 5.4 gal. or 20.5 liters), and yet provide the rear suspension 10400 with sufficient clearance for the main swing arm 402 to move between the fully extended position and the full-bump position.
  • gas tank 10201 has a generally bean shape when seen from either the left side or the right side (see Figures 93 and 96), and a generally L-shape when seen from the front or from the back. More specifically, and as best shown in Figure 93, the gas tank 10201 has a wider upper portion 10600 which is adjacent to the right upper tube 10182 of the rear fender portion 158 when the gas tank 10201 is assembled to the main frame 10012, and a lower, narrower portion 10602.
  • the gas tank 10201 also includes a neck 10634 (shown in Figures 92, 93 and 95), a fuel line, a fuel meter/fuel pump, a strainer and other parts typically required for operatively connecting the gas tank 10201 to the engine 14.
  • a neck 10634 shown in Figures 92, 93 and 95
  • the lower, narrower portion 10602 is vertically aligned with the center of the rear fender 10158, and extends downwardly between the left and right lower frame members 10156, 10176.
  • a recess 10635 is defined in front of the narrower portion, so as to provide space for the differential 10420, therefore allowing full travel of the main swing arm 10402 between a showroom position and a full-bump position.
  • the gas tank 10201 is mounted to the cross-members the rear fender portion 10158 via a plurality of tabs 10654 extending, using threaded fasteners 10658.
  • left and right angular tubes 10151 , 10153, cross-members 10202, 10209, tube members 10224, 10225, as well as sleeve 10228 of the rear fender portion 10158 acts as a guard or bumper for preventing unwanted impact of the main swing arm 10402 moving from the showroom position to the bump position or with obstacles.
  • the exhaust system 10650 is also configured for allowing full travel of the main swing arm 10402 between the showroom position and the full-bump position.
  • the exhaust system 10650 comprises a muffler 10652 mounted to the rear fender portion 10158 of the main frame 10012, generally under the left upper tube 10162 of the fender portion 10158.
  • the muffler 10652 is sized, shaped and positioned on the rear fender portion 10158 such that, together with the configuration of the gas tank 10201 , a space or recess is provided for accommodating the differential 10420 when the rear suspension 10400 is in full bump position.
  • the position of the gas tank 10201 and of the muffler 10652 contribute to balance the fore/aft weight of the ATV 10.
  • the ATV 10 is provided with a different rear suspension configuration 700.
  • the rear suspension 700 is an independent suspension configured to be mounted to the main frame 12.
  • Rear suspension 700 comprises a rear suspension frame 702 to which are attached left and right double A-arm suspensions 704, 706 (only a portion of right double A-arm suspension 706 being shown in Figures 97 and 99).
  • the rear suspension frame 702 comprises left and right tubular members 710, 712, each of the left and right tubular members 710, 712 having a front end 714, 716 attachable to the brackets 406, 408 of the main frame 12 (the brackets 406, 408 being shown in Figures 97 to 102), and a rear end 718, 720. Still referring to Figures 103 to 105, from the front ends 714, 716 to the rear ends 718, 720 thereof, the left and right tubular members 710, 712 converge slightly toward one another.
  • a cross-member 722 Extending between the rear ends 718, 720 of the left and right tubular members 710, 712 is a cross-member 722, in which are defined a pair of holes 724a, 724b for mounting portions of the double A-arm suspensions 704, 706, as it will become apparent below.
  • cross-members 726 and 728 are provided in intermediate locations between the front ends 714, 716 and the rear ends 718, 720 of left and right tubular members 710, 712.
  • rear structure 730 Mounted to the rear cross-member 722 and to the rear ends 718, 720 of tubular members 710, 712 is rear structure 730 having a generally triangular shape when seen from the side (best shown in Figures 103, 104 and 106).
  • This rear structure 730 comprises left and right rearwardly inclined tubes 732, 734, each having a lower end 736, 738, respectively, attached to the cross-member 722.
  • Rearwardly inclined tubes 732, 734 also have upper ends 740, 742 connected to upper tubes 758, 760, respectively.
  • the rear structure 730 has also frontwardly inclined tubes 744, 746 each having a lower end 748, 750 attached to the rear end 718, 720 of the left and right tubular members 710, 712, respectively.
  • the frontwardly inclined tubes 744, 746 also include upper ends 752, 754, respectively.
  • a cross-tube 756 connects the upper ends 752, 754 of the frontwardly inclined tubes 744, 746, and upper tubes 758, 760, each having a front end 762, 764, and rear ends 766, 768, connect the cross-tube 756 connected to the upper ends 740, 742 of the rearwardly inclined tubes 732, 734.
  • Bracket 770 Mounted to the upper ends 740, 742 of the rearwardly inclined tubes 732, 734, and extending between the same, is a bracket 770 having a generally U-shaped cross-section. As best shown in Figures 104, 105 and 108, defined in the bracket 770 are two pairs of holes 772, 774, each pair of holes 772, 774 comprising a first hole 772a, 774a defined in a front flange 776 of the bracket 770 and a second hole 772b, 774b defined in a rear flange 778 of the bracket 770.
  • Cross-member 780 joins member 732 with member 734 between their respective upper and lower ends, 740, 742 and 736, 738. Holes 782a and 782b are defined within cross-member 780 to mount other rear suspension components thereto.
  • Threaded fasteners 784a, 784b are then engaged in holes 772a, 772b, 774a and 774b of the U-shaped bracket 770 and in corresponding holes in the rear cross-member 202 of the fender portion 158 of the main frame 12, thereby securing the rear suspension frame 702 to the main frame 12 of the ATV 10.
  • left and right rear suspensions 704, 706 can be mounted to the rear suspension frame 702.
  • left rear suspension 704 comprises a lower A-arm 800 having an interior end 802 pivotably attached to the rear suspension frame 702 and an exterior end 804 attached to a spindle 812.
  • An upper A-arm 806 has an interior end 808 attached to the rear suspension frame 702 and an exterior end 810 attached to spindle 812.
  • the lower A-arm 800 has a generally U-shape and includes a front arm 814 provided with a bushing (not shown) at the interior end 802, a rear arm 816, also provided with a bushing (not shown) at the interior end 802, and a connecting portion 818 extending at the exterior end and receiving the spindle 812.
  • a shock absorber mounting bracket 820 mounted to the connecting portion 818, in front of the location of the spindle 812, is a shock absorber mounting bracket 820.
  • the upper A-arm 806 has a general shape of a curved A, and comprises a front arm 822 and a rear arm 824. Both front and rear arms 822, 824 further include ends 808 used to connect upper arm 806 to main frame 12. A cross-member 826 extends between the front arm 822 and the rear arm 824 to increase rigidity.
  • the interior ends 802 of the front and rear arms 814, 816, of the lower A-arm 800 are attached to cross-members 726, 722, respectively, using threaded fasteners 830, 832 (shown in Figures 98 and 100) engaging holes 834a, 834b and 724a, 724b (holes 834a, 834b, 724a and 724b being best shown in Figure 103) and the bushings (not shown) found at the interior end 802 of the lower A-arm 800.
  • a shock absorber 839 is attached to the rear left suspension 704.
  • the shock absorber 839 includes a dampener 840, to which is mounted a coil spring 842.
  • a lower end 844 of the dampener 840 is attached to the bracket 820 of the lower A-arm 800 while an upper end 846 is attached to the bracket 492 found at the junction of the upwardly extending left tube 110 and the upper tube 162 of the rear fender portion 158 of the main frame 12.
  • right rear suspension 706 is essentially a mirror image of left rear suspension 704, it will be appreciated that the description of left rear suspension 704 also applies to right rear suspension 706, with proper adaptations.
  • rear suspension 700 can be used instead of rear suspension 24, without having to alter the remaining portions of the frame 12 of the ATV 10. This may prove advantageous in many instances, for instance by offering various rear suspensions in various market segments without requiring substantial changes to the rest of the vehicle, and without the need to substantially reconfigure the assembly line.
  • Figures 113, 1 14 and 115 show further features of a frame 35012 for the ATV 10, the main frame 35012 comprising a front portion 1610, a middle portion 1620 and a rear portion 1700 extending along a longitudinal axis Li- Li between a rear proximal end 1701 and a rear distal end 1799.
  • the front portion 1610 is configured to receive left and right front shock absorbers (not shown in Figures 113 to 115) and the middle portion 1620 is configured to receive an engine (not shown in Figures 113 to 1 15).
  • Figure 113 shows the rear portion 1700 of the main frame 35012 comprising a rear bumper 2000.
  • bottom portions 35134, 35138 will sometimes be referred to as left and right “members” 35134, 35138 being understood that the terms “bottom portions” are used interchangeably with “members” to designate the same corresponding structures identified with the same reference numerals.
  • the rear portion 1700 of the main frame 35012 comprises a left member 35134 adjacent the rear proximal end 1712, the left member 35134 extending upwardly from a left bottom end portion 1714 to a left top end portion 1716, and a right member 35138 adjacent rear proximal end 1722, the right member 35138 extending upwardly from a right bottom end portion 1724 to a right top end portion 1726.
  • the left and right members 35134, 35138 also comprises left and right rear surfaces 1711 , 1721 and left and right bottom holes 1713, 1723 and left and right top holes 1715, 1725.
  • the left and right members 35134, 35138 comprise left and right bottom projections 1717, 1727 (best seen in Figure 121) extending forwardly along left and right bottom mounting axes LBMA, RBMA and left and right top projections 1719, 1729 extending forwardly along left and right top mounting axes LTMA, RTMA.
  • the left and right bottom projections 1717, 1727 comprise left and right inner walls 1750, 1752 defining left and right bottom channels 1751 , 1753 aligned with the left and bottom holes and the left and right top projections 1719,
  • 1729 comprise left and right inner walls 1819, 1829 defining left and right top channels 1919, 1929 aligned with the left and right top holes (as best seen in Figure 120).
  • the rear portion 1700 of the frame 35012 also comprises a left transversal arm
  • the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 further comprise left and right rear surfaces 1734, 1744, as best seen in Figures 1 15 to 117.
  • the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 are mounted to the left and right bottom end portion 1714, 1724 of the left and right members 35134, 35138.
  • the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 are mounted to the left and right rear surfaces 1711 , 1721 of the left and right members 35134, 35138.
  • the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 comprise left and right proximal ends 1732, 1742 extending longitudinally along the left and right bottom mounting axes LBMA, RBMA and forwardly up to the left and right members 35134, 35138.
  • the left and right proximal ends 1732, 1742 of the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 comprise left and right circular walls 1733, 1743 extending along the left and right bottom mounting axes LBMA, RBMA and defining left and right housings 1735, 1745.
  • the rear portion 1700 of the frame 35012 also comprises left and right bushings 1737, 1747 adapted to be mounted in the left and right housings 1735, 1745.
  • the rear portion 1700 of the main frame 35012 comprises a hitch receiver 1830 comprising a central projection 1831 extending rearwardly along the longitudinal axis L Li from a proximal end portion 1832 to a distal end portion 1833, left and right bottom protrusions 1840, 1850 extending transversely from the distal end portion 1833, and left and right top protrusions 1841 , 1851 extending transversely from the distal end portion 1833 (as best seen in Figures 118 and 121).
  • the central projection 1831 comprises exterior and inner walls 1834, 1835 and the inner wall 1834 of the central projection 1831 defines a housing 1836 for receiving an elongated portion of a hitch HI.
  • the elongated portion of the hitch HI may comprise a hole h and the central projection 1831 of the hitch receiver 1830 may comprise a hole 1837 for allowing locking of the hitch HI with respect to the hitch receiver 1830 with a locking bar LB comprising a removable lock L that is actuated with a key or with a pin (not shown) for instance.
  • the central projection may extend along a length of between about 10 cm and about 20 cm.
  • the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 comprise left and right bottom apertures 1842, 1852 at respective distal ends and the left and right top protrusions 1841 , 1851 of the hitch receiver 1830 comprise left and right top apertures 1843 (not shown), 1853 at respective distal ends.
  • 1740 extend between the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 and the left and right members 35134, 35138.
  • 1741 of the left and right transversal arms 1730, 1740 and the left and right top protrusions 1841 , 1851 of the hitch receiver 1830 are mounted to the left and right members 35134, 35138. More particularly, the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 are mounted to the left and right rear surfaces 1734, 1744 of the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 and the left and right top protrusions 1841 , 1851 of the hitch receiver 1830 are mounted to the left and right rear surfaces 1711 , 1721 of the left and right members 35134, 35138.
  • the hitch receiver comprises a left flange 1845 between the left bottom and top protrusions 1840, 1841 , a right flange 1847 between the right bottom and top protrusions 1850, 1851 , a left bottom flange 1846 between the left bottom protrusion 1840 and the central projection 1831 and a right bottom flange 1848 between the right bottom protrusion 1850 and the central projection 1831 .
  • the left and right flanges 1845, 1847 may comprise left and right rear walls 1854, 1856, extending upwardly from the left and right bottom protrusions 1840, 1850 and left and right top walls 1855, 1857, extending forwardly from the left and right rear walls 1854, 1856, up to the left and right top protrusions.
  • Each of the left and right flanges 1845, 1847 may be an L-shaped flange.
  • Each of the left and right flanges 1845, 1847 and the left and right bottom flanges 1846, 1848 are provided to add rigidity to the left and right bottom protrusions 1840, 1850 and the left and right top protrusions 1841 , 1851 .
  • Each of the left and right flanges 1845, 1847 and the left and right bottom flanges 1846, 1848 may extend up to the distal ends of the left and right bottom protrusions 1840, 1850 and the left and right top protrusions 1841 , 1851.
  • the left and right rear walls 1854, 1856 of the left and right top protrusions 1841 , 1851 and the left and right bottom protrusions 1840, 1850 may comprise openings 1858 for reducing weight while still providing rigidity to the left and right bottom protrusions 1840, 1850 and the left and right top protrusions 1841 , 1851 .
  • the rear portion 1700 of the frame 35012 further comprises left and right bottom fasteners 12510, 12520 mounted in the left and right bottom apertures 1842, 1852 of the hitch receiver 1830, in the left and right bushings 1737, 1747 and in the left and right bottom holes 1713, 1723 of the left and right members 35134, 35138 and left and right top fasteners 12530, 12540 mounted in the left and right top apertures 1843, 1853 of the hitch receiver 1830 and in the left and right top holes 1715, 1725 of the left and right members 35134, 35138 for affixing the hitch receiver 1830 to the left and right members 35134, 35138 while allowing pivotable movement of the left and right transversal arms 1730, 1740 relative to the left and right bottom mounting axes LBMA, RBMA.
  • the left and right bottom fasteners 12510, 12520 may comprise left and right bottom bolts 12511 , 12521 comprising left and right distal threaded ends 12512, 12522 and left and right bottom nuts 12513, 12523 and the left and right top fasteners may comprise left and right top bolts 12531 , 12541 comprising left and right distal threaded ends 12532, 12542 and left and right top nuts 12533, 12543.
  • the left and right distal threaded ends 12512, 12522 of the left and right bottom bolts 12511 , 12521 extend forwardly outside the left and right bottom channels 1751 , 1753 of the left and right bottom projections of the left and right members and the left and right distal threaded ends 12532, 12542 of the left and right top bolts 12531 , 12541 extends forwardly outside the left and right top channels 1919, 1923 of the left and right top projections of the left and right members such that the left and right bottom nuts 12513, 12523 are mounted to the left and right distal threaded ends 12512, 12522 of the left and right bottom bolts 12511 , 12521 and the left and right top nuts 12533, 12543 are mounted to the left and right distal threaded ends 12532, 12542 of the left and right top bolts 12531 , 12541 for securing the hitch receiver 1830 onto the left and right members 35134, 35
  • the left proximal end 1731 of the left transversal arm 1730 comprises a left-rear external circular wall 1733 facing the left bottom protrusion 1840 of the hitch receiver 1830 and the right proximal end 1741 of the right transversal arm 1740 comprises a right rear external circular wall 1743 facing the right bottom protrusion 1850 of the hitch receiver 1830.
  • the left and right rear circular external walls 1733, 1743 and the left and right bottom protrusions 1840, 1850 define left and right rear spaces therebetween.
  • the left and right bushings 1737, 1747 may comprise left and right rear external circular walls 1754, 1756 being adapted to abut against the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 and left and right circular walls 1755, 1757 being adapted to be mounted in the left and right bottom apertures 1842, 1852 of the left and right bottom protrusions 1840, 1850.
  • left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 are pivotably mounted to the left and right members 35134, 35138 to allow pivotable movement of the left and right transversal arms 1730, 1740 upon upward or downward movement of the left and right wheels 22a, 22b while no torsional effort is transmitted to the hitch receiver 1830 that is independently mounted to the left and right members 35134, 35138.
  • the rear portion 1700 of the frame 35012 also comprises a left shock absorber 1760 adjacent the rear proximal end 1712, the left shock absorber 1760 extending upwardly from a left bottom end portion 1761 to a left top end portion 1762, and a right shock absorber 1770 adjacent rear proximal end 1722, the right shock absorber 1770 extending upwardly from a right bottom end portion 1771 to a right top end portion 1772.
  • the left and right bottom end portions 1761 , 1771 of the left and right shock absorbers 1760, 1770 are mounted to the left and right transversal arms 1730, 1740 such that upon upward ordownward movement of the left and right wheels 22a, 22b, the left and right transversal arms 1730, 1740 pivot relative to the left and right members 35134, 35138 and the left and right shock absorbers 1760, 1770 are compressed or expanded.
  • the left and right transversal arms may be left and right bottom transversal arms and the rear portion 1700 of the frame 35012 may comprise left and right top transversal arms 1780, 1790 adjacent the rear proximal end 1701.
  • the left and right top transversal arms 1780, 1790 extend from left and right top proximal ends 1781 , 1791 to left and right top distal ends 1782, 1792 (not shown).
  • the left and right top proximal ends 1781 , 1791 of the left and right top transversal arms 1780, 1790 are pivotably mounted to the left and right members 35134, 35138 and the left and right top distal ends 1782, 1792 of the left and right top transversal arms 1780, 1790 are mounted to the left and right wheels 22a, 22b.
  • the left and right bottom transversal arms 1730, 1740 and the left and right top transversal arms 1780, 1790 pivot relative to the left and right members 35134, 35138 and the left and right shock absorbers 1760, 1770 are compressed or expanded.
  • the left and right top end portions 1762, 1772 of the left and right shock absorbers 1760, 1770 may be mounted to left and right top members 35162, 35182 extending forwardly from the rear proximal end 1701 of the rear portion 1700 of the frame 35012.
  • the left and right members 35134, 35138 may be first left and right members
  • the left and right bottom transversal arms 1730, 1740 may be first left and right bottom transversal arms
  • the left and right top transversal arms 1780, 1790 may be first left and right top transversal arms
  • the rear portion 1700 of the frame 35012 may comprise a second left member 1950 (not shown) spaced forwardly relative to the first left member 35134 and a second right member 1960 spaced forwardly relative to the first right member 35138, a second left bottom transversal arm 1970 extending transversely between a second left bottom proximal end portion 1971 (not shown) and a second left bottom distal end portion 1972, a second right bottom transversal arm 1980 extending transversely between a second right bottom proximal end portion 1981 and a second right bottom distal end portion 1982, a second left top transversal arm 1975 extending transversely between a second left top proximal end portion 1976 (not shown) spaced forwardly relative to the first right member 35
  • the second left and right bottom proximal ends 1971 , 1981 of the second left and right bottom transversal arms 1970, 1980 are pivotably mounted to the second left and right members 1950, 1960 and the second left and right bottom distal ends 1972, 1982 of the second left and right bottom transversal arms 1970, 1980 are mounted to the left and right wheels 22a, 22b.
  • the steering assembly 28 comprises a steering column 900 having an upper end 902 and a lower end 904. Attached to the upper end 902 of the steering column 900 is a handlebar bracket 906 for mounting a handlebar clamp assembly 908, in which is clamped a handlebar 910 including controls for operating the ATV 10 (not shown in Figures 125 to 134).
  • a steering column mounting bracket 912 in the form of hemispherical bearing, for operatively attaching the upper end 902 of the steering column 900 to the main frame 12. More specifically, a pair of semi-spherical members (not shown) are attached to the upper end 902 of the steering column 900, the two semi-spherical members being received in a U-Shaped clamp member 917 attached to the cross-tube 118a of the main frame 12, via a pair of tubular members 916, 918 (shown in Figures 13 and 127).
  • the configuration of the steering column mounting bracket 912 allows rotational movement about the rotation axis R1-R1 of the steering column 900, whetherthe steering column 900 is perfectly aligned with main frame 12 or should there be a slight misalignment, for instance due to the assembly of the steering assembly 28 to the main frame 12 or because the main frame 12 and/or other components of the ATV 10 are subject to torsion and twisting during the operation of the ATV 10.
  • the steering column 900 is attached to a power steering assembly 920, in this case a Dynamic Power Steering (DPS).
  • a power steering assembly 920 comprises a male connector 921 (best shown in Figure 127) for receiving therein a splined lower end 904 of the steering column 900.
  • Extending on a bottom end 924 of the power steering assembly 920 is a shaft 926, the shaft 926 having a lower end 928 provided with a hemispherical bearing 930 for attaching the power steering assembly 920 to the main frame 12, and a pitman arm 932 attached to the shaft 926.
  • a casing 934 for housing the internal parts of the power steering assembly 920, the casing 934 being mounted to the main frame via a pair of C-shaped brackets 936, 937 secured to the bottom end 924 of the steering assembly 920, as it will become apparent below.
  • the pitman arm 932 is configured for operatively receiving left and right tie rods 940, 942, and to collaborate with a pair of stoppers 944, 946 extending from the main frame 12 and configured to restrict the turn angle of the front wheels 16a, 16b when the front suspension 18 of the ATV 10 is in a showroom position (shown in Figures 125 to 130). More specifically, and still referring to Figure 128, the pitman arm 932 has a generally keyhole shape and comprises a hub 948 attached to the shaft 926 of the power steering assembly 920 and trapezoidal mounting plate 950 extending radially from the hub 948, towards the rear of the ATV 10.
  • the trapezoidal mounting plate 950 comprises a first end 952 in contact with the hub 948, two side ends 954, 956 extending from the first end 952, away from one another, and a gently curved rear end 958.
  • the side ends 954, 956 of the trapezoidal plate 950 define angles adapted to match left and right stoppers 944, 946 extending from the frame 12 of the ATV 10, on each side of the left and right side 954, 956 of the trapezoidal mounting plate 950.
  • the wheels 16a, 16b of the ATV 10 are positioned to move in a straight ahead direction) an equal space is defined between each of the left and right side ends 954, 956 of the plate 950 and the left and right stoppers 944, 946.
  • the steering assembly 28 is steered in a full-left steer (best shown in Figure 126, 128, 129 and 130)
  • the right side end 956 of the trapezoidal plate 950 abuts against the right stopper 946, thereby preventing further steering of the front wheels 16a, 16b toward the left.
  • the left side end 954 of the trapezoidal plate 950 abuts against the left stopper 944, thereby preventing further steering of the front wheels 16a, 16b toward the right.
  • the size, shape and position of the trapezoidal plate 950, as well as of the stopper 944, 946 extending from the main frame 12, can be configured to reduce the stress on the various joints of the steering assembly 28 while allowing a certain degree of freedom to steer the ATV 10 in left and right directions.
  • Left tie rod 940 comprises a right end 962, mounted to the pitman arm 932 via a spherical bushing or ball joint 964, and a left end 960 attached to the left knuckle 300, also via a spherical bushing 966.
  • the right tie rod 942 comprises a left end 970, attached to the pitman arm 932 via a spherical bushing 972, and a right end 974 attached to the knuckle 300 of the right wheel 16b (not shown in Figures 127 and 128), also via a spherical bushing 976.
  • the exterior end 310, corresponding to second end 310 of Figure 59, of the lower A-arm 296 is provided with a stopper 980 extending from the rear arm of lower A-arm 296, proximate to the junction with the front arm thereof.
  • the stopper 980 extends outwardly (/.e. in a left, sideways direction).
  • the stopper 980 comprises a slightly inclined abutment face 982, configured to collaborate with a knuckle projection 990 to restrict the turn movement of the left wheel 16a when the suspension moves from a showroom position (shown in Figures 125 to 130) to a full-droop position (shown in Figures 131 to 133) or a full-bump position (not shown) and the steering assembly 28 is in a full-steer position toward the left, as it will become apparent below.
  • the knuckle projection 990 extends rearwardly from the knuckle 300 and comprises a slightly inclined interior face 992.
  • the angle of the interior face 992 of the knuckle projection 990 relative to a vertical plan matches the angle of the abutment face 982 of the stopper 980.
  • This engagement forces the steering assembly 28 to rotate towards the neutral (straight ahead) steering position of the steering assembly 28 and causes the right end 956 of the trapezoidal plate 950 of the pitman arm 932 to move slightly away from the right stopper 946 (shown in Figure 133).
  • the stopper 980 and knuckle 300 configuration collaborate to slightly reduce the degree of freedom of the steering assembly 28 in one direction or the other, which in turn contributes to reduce the stress on various joints of the steering assembly 28 during the operation of the ATV 10, especially when the steering assembly 28 is in full steer position and the front suspension is called to move between the showroom, full droop and/or full-bump positions.
  • left and right front suspension subassemblies 292, 294 being mirror images of one another, a similar description of stopper 980 and knuckle projection 990 also applies to right front suspension subassembly 294, with proper adaptations.
  • the assembly of the power steering assembly 920 (in this illustrated embodiment, a DPS) to the main frame 12 may be challenging in some instances. Indeed, the rotation axis R1-R1 of the steering column 900 and of the male connector 921 (shown in Figure 127) of the power steering assembly 920 must be aligned within a certain degree of tolerance, since a misalignment can lead to premature damage to the power steering assembly 920. As such, manufacturers tend to require that the assembly of power steering to the frame ofthe ATV follow a specific sequence for securing the various fasteners, which can prove challenging because the assembly line workers or repair technicians may omit to follow this specified sequence.
  • the power steering assembly 920, and the brackets for mounting the same to the main frame 12 of the ATV 10 are configured to slightly deform when the power steering assembly 920 is mounted to the main frame 12, such that when the lower end 904 of the steering column 900 engages the male connector 921 (best shown in Figure 127), the power steering assembly 920 is forced into a proper alignment with the axis of the steering column 900, and persistently maintains such an alignment.
  • the relative flexibility of the assembly of the power steering assembly 920 and the bracket for mounting the same to the main frame 12 of the ATV 10 contribute to increase the manufacturing tolerances and avoid the need for a specific sequence of assembly of the fasteners used to secure the power steering to the frame.
  • the main frame 12 of the ATV 10 is provided with the pair of angular left and right tube members 1001 , 1003 connecting left and right front upwardly extending tubes 108 and 112 to the crossmember 147.
  • left and right portions 1004, 1006 of the mounting plate 1000 define stoppers 944 and 946, respectively.
  • the mounting plate 1000 is provided with a circular hole 1005, configured to receive the spherical bearing 930 at the lower end 928 of the pitman arm 932 mounted to shaft 926 extending from the power steering assembly 920, as well as a plurality of holes 1007a-1007c for receiving therein a corresponding plurality of threaded fasteners 1009a-1009c for securing the C-shaped brackets 936, 937 to the mounting plate 1000.
  • the C-shaped brackets 936, 937 each have an upper end 1010, mounted to the casing 934 of the power steering assembly 920, at the lower end 924 thereof, using threaded fasteners 1011 a-1011 c, and a lower end 1012 secured to the mounting plate 1000 by way of threaded fasteners 1009a-1009c.
  • a generally vertical plate portion 1014 extends between the upper end 1010 and the lower end 1012 of the C-shaped bracket 936, the main portion 1014 being configured to allow an elastic deformation of the C-shaped bracket 936, which elastic deformation is induced in case of misalignment of the power steering assembly 920 with the main frame 12.
  • the C-shaped bracket along with the spherical bearing 930 at the lower end 928 of shaft 926 and the spherical bracket 912 proximate to the upper end 902 of the steering column 900, allow for a degree of misalignment of the power steering assembly 920 relative to the main frame 12 while maintaining the operation of the steering assembly 28 and contributing to reduce damages to the power steering assembly 920 that may be caused by such a misalignment.
  • the ATV 10 is provided with an airbox 7200.
  • the airbox 7200 is generally V-shaped (when seen from the top in Figure 140 or bottom in Figure 141) and comprises, as best shown in Figures 138 and 139, a V-shaped base portion 7202 and a V-shaped top portion 7204.
  • V-shaped base portion 7202 and a V-shaped top portion 7204 define a housing 7206 which houses air filter 7208, as will be described in detail below.
  • the housing 7206 defined by the base portion 7202 and the top portion 7204, comprises a left intake section 7210, a right outtake portion 7212, each having front ends 7214, 7216 respectively, and rear ends 7218, 7220 respectively. Extending between the rear ends 7218, 7220 of the left intake portion 7210 and the right outtake portion 7212, is a conduit portion 7222. Further, at the rear end 7220 of the right outtake portion 7212 is an outtake conduit 7222, for operatively connecting the airbox 7200 to the engine 14 via a pipe (not shown). Between the left intake portion 7210 and the right outtake portion 7212, a space 7226 is provided for allowing the passage of the steering assembly 28 as is best shown in Figure 141 .
  • the left intake section 7210 of the housing 7206 comprises a bottom pocket wall 7230 defined by the left portion of the base section 7202. Received in the bottom pocket wall 7230 is a first air intake conduit 7232.
  • the first intake conduit 7232 is curved and defines an arc of a circle, and comprises a first end 7234, and a second end 7236, which lower end 7236 of the first intake conduit 7232 is located below the conduit portion 7222 of the housing 7206.
  • the left intake section 7210 of the housing 7206 also comprises a top pocket wall 7240 defined by the left portion of the top portion 7204, and an intake conduit 7242.
  • the conduit 7242 of the top portion 7204 is in fluid communication with the first intake conduit 7232 of the base portion 7202, and allows ambient airto enterthe left portion of the airbox 7200.
  • the air filter 7208 Operatively mounted at the rear end 7219 of the left portion 7210, in fluid connection with the conduit portion 7222 of the airbox 7200, is the air filter 7208.
  • the air filter 7208 is threadably mounted to the housing 7206 via a threaded conduit 7243 mounted to the top portion 7204, in registry with the conduit portion 7222 (see Figure 142).
  • the air filter 7208 properly mounted to the top portion 7204 of the airbox 7200 is located above the second end 7236 of the first intake conduit 7232 when the base and top portions 7202, 7204 are assembled together, such that any unwanted, heavier material entering the conduit 7242 of the top portion 7204 and carried through the first intake conduit 7232 of the base 7202 will remain in the bottom pocket wall 7230 of the airbox 7200 because of gravity, rather than being conveyed toward the air filter 7208.
  • an opening 7250 is defined in the top pocket wall 7240. Opening 7250 is sealed closed by a gasket 7252 and a cover 7254 using a plurality of clamps 7256a-7256d.
  • the clamps 7256a-7256d are opened and the cover 7254 is removed, thereby giving access to the air filter 7208 and the left portion 7210 of the housing 7206.
  • the gasket 7252 and cover 7254 are properly repositioned, and the clamps 7256a-7256d are secured to maintain the cover 7254 in position.
  • the second intake conduit 7262 has a rear end 7264 operatively connected to the conduit portion 7222 of the housing 7206, and a front end 7266 extending toward the front end 7216 of the right, outtake portion 7212. Located below the second intake conduit 7262 is the outtake conduit 7224.
  • the conduit portion 7222 of the housing 7206 operatively connects the air filter 7208 to the second intake conduit 7262, and comprises a lower conduit portion 7270 defined by the base portion 7202 and an upper conduit portion 7272 defined by the upper portion 7204 of the airbox 7200.
  • the upper and lower portions 7272, 7270 of the conduit portion 7222 define somewhat of a curved pipe.
  • the base portion 7202 is joined to top portion 7204 using threaded fasteners, clips, glue and the like.
  • the air filter 7208 can then be positioned in the housing 7206 and the opening 7250 closed using gasket 7252 and cover 7254 by way of clamps 7256a-7256b.
  • the airbox 7200 is mounted to the left and right upper tubes 104, 106 of the main frame 12, proximal to cross-member 118a, using threaded fasteners. In this location, the space 7226 defined between the left and right portions 7210, 7212 of the airbox provides room for receiving the steering column 900 of the steering assembly 28.
  • FIG. 143 to 159 there is shown an embodiment of an ATV similar to ATV 10, comprising an improved service center 3100 and an improved airbox 3200 accessible through the service center 3100.
  • the service center 3100 is located in the hood area of the ATV 10, in front of a steering device 3128 (e.g., handlebar 910).
  • the service center 3100 is formed from several surrounding body panels 3102.
  • a removable top cover 3110 covers the body panels 3102 to close the service center 3100 and to cover and protect the elements therein.
  • the service center 3100 regroups and provides access to the airbox 3200, an air entry or inlet 3203 leading into the airbox 3200, a coolant bottle 3010, a fuse box 3104 and a CVT air entry 3020.
  • the top removable cover 3110 may be configured for easy removal, for example using toolless % turns at the rear and a toe-in at the front. Other easy removal configurations for the top removable cover 3110 will be apparent, including without limitation the use of snap engagement means, hoop and loop fasteners, magnets and the like.
  • the cover 3110 may further comprise additional components such as electrical components, a display for displaying information concerning the vehicle systems, communication devices to the driver and/or electric outlets 3106 such as a 12v female plug.
  • Wires 3108 supplying such components with power and/or data can extend from the ATV to the cover 3110 and comprise such a length as to allow the cover 3110 to be detached and placed to one side to access the components within the service center 3100 without having to disconnect the wires.
  • the wires can be detachably connected to the ATV and or to the cover 3110, allowing the wires to be disconnected and the cover 31 10 to be removed.
  • the airbox 3200, the air entry or inlet 3203 leading into the airbox 3200, the coolant bottle 3010, the fuse box 3104 and the CVT air entry 3020 are all located in the service center 3100, in front of the steering assembly 28 provides access to all these components without the need to dismantle other portions of the ATV, for instance cowlings or the seat.
  • This configuration of service center 3100 proves to be particularly useful to carry out maintenance of an air filter 3220.
  • the service center 3100 provides access to airbox 3200, which is also configured to allow accessing and/or replacing the air filter 3220 via the service center 3100.
  • a removable airbox cover 3212 covering an opening 3210 into the airbox 3200 that can be removed to get access to the air filter 3220.
  • the air filter 3220 can be removed from the airbox 3200 through the opening 3210 and the service center 3100.
  • the airbox 3200 generally comprises a housing 3120 comprising a top portion 3201 and a bottom portion 3202, the top portion 3201 being configured to receive an air entry 3203.
  • the top portion 3201 further comprises the opening 3210 and is configured to receive the cover 3212 to abut the opening 3210. Air leaves the airbox 3200 towards an engine, such as engine 3050, through an engine air entry 3900.
  • the airbox 3200 is generally located in front of the steering device (e.g., handlebar 910) of ATV 10.
  • the airbox 3200 presents several advantages over airboxes of the prior art, including a shorter air intake path, greater ease of maintenance and the possibility of accessing the interior of the airbox 3200, including the air filter 3220, through the service center 3100.
  • the airbox cover 3212 is configured to abut the opening 3210 and to be removably secured to the top portion 3201 of the airbox 3200.
  • the airbox cover 3212 is held in place with securing means 3211 configured to be manipulated and removed without the use of tools, for example by one or more over-center clips.
  • the cover 3212 further comprises at least one protrusion 3213 extending into the airbox 3200.
  • the protrusions 3213 may extend substantially vertically, or diagonally, or substantially parallel to the walls of the housing.
  • the protrusions 3213 may further comprise notches, recesses or indentations 3214, the advantages of which will be apparent below.
  • the airbox 3200 is configured to receive an air filter 3220 through opening 3210.
  • the air filter 3220 extends between a distal end 3221 , situated distally from engine air entry 3900, and a proximal end 3222, situated proximally to the engine air entry 3900.
  • the recesses or indentations or notches 3214 are configured to abut and engage at least a portion of the distal end 3221 , thereby holding the air filter 3220 in position.
  • the airbox 3200 may further comprise a Helmholtz resonator 3230, configured to reduce noise and vibration, such as engine noise and cavitation vibrations, from the engine and from other components of the ATV 10. This is advantageous as it increases the comfort of a user of ATV 10 while ATV 10 is in operation.
  • a Helmholtz resonator 3230 configured to reduce noise and vibration, such as engine noise and cavitation vibrations, from the engine and from other components of the ATV 10. This is advantageous as it increases the comfort of a user of ATV 10 while ATV 10 is in operation.
  • Figure 158 shows the positioning of the features previously described within the airbox 3200 when the airbox 3200 is installed and closed.
  • Air filter 3220 extends from engine air entry 3900 towards the front of airbox 3200, and is configured to connect at its distal end 3221 to means for conveying air from the air intake 3203 to the air filter.
  • Airbox cover 3212 is secured to the airbox top portion 3201.
  • Protrusions 3213 extend into the airbox body and recesses 3214 engage the top portion of the distal end 3221 of air filter 3220.
  • the distal end 3221 is thereby sandwiched between the protrusions 3213 and, for example, Helmholtz resonator 3230, or any other feature suitable to engage a bottom portion of the distal end 3221 of filter 3220 to hold it in position in cooperation with protrusions 3213.
  • FIG. 157 an advantageous way of removing filter 3220 from airbox 3200 is shown.
  • filter 3220 When installed, as shown in Figure 157, filter 3220 abuts engine air entry 3900.
  • the airbox cover 3212 is removed, leaving opening 3210.
  • Filter 3220 is displaced from engine air entry 3900 (shown in Figure 158).
  • Engine air entry 3900 may be configured to engage the air filter 3220 by means of a protruding conduit 3901 .
  • Other means of connecting and/or securing an air filter 3220 to engine air entry 3900 will be apparent.
  • filter 3220 may be at least partially rotated to a more vertical orientation for ease of removal through the opening 3210 (moving for the position shown in Figure 158 to the position shown in Figure 159). As best shown in Figure 159, the air filter 3220 is then removed through opening 3210, located within service center 3100 of ATV 10.
  • an ATV 5100 according to another is shown.
  • the ATV 5100 is configured to be operated on various terrains and in a variety of conditions, and in certain depths of water, for instance by crossing a stream and/or in muddy conditions, for example after heavy rainfalls, during a thaw period, in wetlands, or otherwise in conditions that favour a muddy terrain. It is therefore advantageous to provide features allowing for easy maintenance of key components in such conditions, to improve vehicle performance and user comfort.
  • the ATV 5100 may comprise components such as frames, engines, bumper assemblies and other components as described above. In particular.
  • ATV 5100 also comprises a radiator 5200 (see Figures 163, 164 and 166) positioned forwardly from the seat 5110 and steering device 5120 (i.e., handlebar 910) and at an elevated position, substantially level with the handlebar 910 and the seat 5110.
  • the radiator 5010 is positioned at an elevated position with respect to the engine and frame components, generally above the front wheels, such that the radiator is at a higher distance from the ground and from the terrain as compared to traditional ATVs.
  • the radiator 5200 is covered by a radiator cover assembly 5202 comprising a top cover 5210 and side portions 5212.
  • the cover 5210 comprises air inlet means 5211 on a front-facing side 5205 which allow the cover 5210 to provide oncoming air with access to the radiator.
  • the side portions 5212 rise substantially vertically from the wheel fenders 5213, on each side of the cover 5210 such that the generally vertical side portions 5212 and the cover 5210 create a ram air effect, ramming oncoming air onto the radiator 5200.
  • the cover 5210 when the ATV is in use, allows airflow 5300 to enter a space between the cover 5210 and the radiator 5200.
  • the pressure exerted by the forward motion of the ATV 5100 rams the airflow 5300 over the radiator 5200, improving its performance.
  • the cover 5210 may be pivotably attached to the radiator 5200 or to another structural element of the ATV 5100 in proximity to the radiator 5200.
  • a pivotable attachment of the cover 5210 is advantageous in that it allows for easy access and cleaning of the radiator 5200.
  • the cover 5210 may pivot about pivot points 5214, situated proximate to the air inlets 5211 .
  • the cover 5210 may comprise latching means 5215, for example latches, situated at an end proximate the user of the ATV 5100 with respect to the pivot points 5214 (see Figures 164 and 167).
  • the latches 5215 may be made from any suitable material, for example rubber, and secure the cover 5210 in a closed position when the ATV 5100 is in use. By pivoting upward and forward, the cover 5210 gives a user of the ATV 5100 easier access to the radiator to wash and/or remove debris that could be blocking the radiator.
  • the cover 5210 may comprise additional elements to enhance the user’s experience or provide easy access to necessary tools or information.
  • the cover 5210 may further comprise, situated within its inner portion (or inner face) 5401 , a toolkit 5400, which may comprise an assortment of useful tools such as screwdrivers, pliers, wrenches and the like.
  • the toolkit may comprise tools matching the sizes and other characteristics of components of ATV 5100.
  • the toolkit 5400 may be secured to the inner portion of the cover 5210 by any suitable means. For instance, it may be secured by means of a pivotable bar or latch 5410. Other securing means will be apparent.
  • the ATV 10 is packed and shipped in a crate 1450, illustrated in Figures 177 and 178.
  • the crate 1450 is sized to be stacked on top of two identically sized crates 1450, where the height of the three crates 1450, stacked one on top of the others, does not exceed a predetermined maximum shipping height.
  • the crates 1450 once stacked are sized not to exceed a maximum shipping height of 105 inches (about 2667 mm). It is contemplated that the crates 1450 could be sized to comply with different or multiple specific restrictions for different modes of shipment or changes in transport regulation.
  • the crate 1450 therefore has an exterior height H 2 (see Figure 178) which is equal to or less than an internal height of 105 inches (2667 mm) of a shipping container.
  • the exterior height H 2 of each crate 1450 has a height of 34.4 inches (874.125 mm) such that three crates 1450 stacked onto one another have a total exterior height of 103.24 inches (2622.30 mm).
  • the crate 1450 comprises a steel frame 1452 on which is wrapped a plastic cover (not shown in Figures 177 and 178).
  • the steel frame 1452 comprises a bottom frame portion 1460 comprising left and right frame members 1454, 1456 (only left frame member 1454 being shown in Figure 177), each comprising a front end 1458 and a rear end 1462.
  • the bottom frame portion 1460 also comprises a front cross-member 1464 extending between the left and right frame members 1454, 1456, at the front ends 1458 thereof, and a rear cross-member 1466, also extending between the left and right frame members 1454, 1456, but at the rear ends 1462 thereof.
  • the bottom frame portion 1460 also includes a pair of rectangular tube members 1470, 1472, extending between the left and right frame members 1454, 1456. Rectangular tube members 1470, 1472 are configured to be used by a forklift to move the crate 1450, as well as the ATV 10 and the crate 1450 when the ATV 10 is packed therein.
  • the tubes 1470, 1472 extending across the width of the bottom frame portion 1460 further provides weight bearing surfaces on which most of the weight of the ATV 10 will rest when the ATV 10 is fully packed in the crate 1450, as will be described in more detail below.
  • brackets 1476, 1478 and 1480 are Provided at the front and rear ends 1458, 1462, as well as in an intermediate location 1474 between the front and rear ends 1458, 1462.
  • the crate 1450 also includes left and right side wall frame portions 1482, 1484, and a top frame portion 1486.
  • the left and right side wall frame portions 1482, 1484 each comprise a front frame member 1488, a rear frame member 1490 and an intermediate frame member 1492, all extending upwardly and vertically from the left and right frame members 1454, 1456, at the front end 1458, rear end 1462 and intermediate location 1474, respectively, and are attached to left and right frame members 1454, 1456 via brackets 1476, 1478 and 1480.
  • the top frame portion 1486 comprises longitudinal frame members 1500, 1502 having a front end 1504 and a rear end 1506, the top longitudinal frame member 1500, 1502 having generally the same length as frame members 1454, 1456 of the bottom frame portion 1460.
  • Top frame portion 1486 also includes a front cross-member 1508, a rear cross-member 1510 and a pair of intermediate cross-members 1512, 1514.
  • Bracket 1520, 1522 and 1524 are configured for securing the top frame portion 1486 to upper ends of front frame member 1488, intermediate frame member 1492 and rear frame member 1490 of the left and right side wall frame portions 1482, 1484.
  • the exterior of the frame has a height H 2 and an internal height H 3
  • the ATV 10 when at rest and ready to use (/.e. in a showroom configuration), has a full ATV height Hi measured from the ground up to the top of the steering assembly 28, as is illustrated in Figure 6. By comparing the full ATV height Hi to the maximum internal height H 3 , it can be seen that the ATV 10 cannot be packed into the crate 1450 in a configuration where the ATV is at its full ATV height Hi. [00467] In order to pack the ATV 10 in the crate 1450 according to the method of the present embodiment, the ATV 10 is compressed into a packing configuration by compressing the front and rear suspensions 18 and 24 or 700, and the handlebars 910 are lowered, such that the ATV 10 has a packing height H 4 .
  • the ATV 10 is shown in the packing configuration inside the crate 1450 in Figures 177 and 178. It should be noted that the height H 4 from the ground to the top of the ATV 10, when in the packing configuration, may not necessarily be less than the maximum internal height H 3 of the crate 1450. Compression of the front and rear suspensions 18 and 400 or 700 to bring the ATV 10 into the packing configuration will be described in more detail.
  • the front and rear suspensions 18 and 400 or 700 are compressed using four tie-down straps (not shown), each tie-down strap in this embodiment being preferably a ratchet type tie-down strap, such as those described in United States Provisional Patent Application No. 62/538,922 and United States Patent Application No. 15/681 ,943, both entitled “Method of Packing a Vehicle in a Crate for Shipment,” filed on July 31 , 2017, and on August 21 , 2017, respectively, the entirety of which is incorporated herein by reference.
  • the ATV 10 is in the packing configuration when lower left and right tubes 100, 102 of the main frame 12 of the ATV 10 abuts the rectangular tubes 1470, 1472 of the crate 1450.
  • height H 4 needs to be equal to or less than the maximum internal height H 3 of the crate 1450.
  • the weight of the ATV 10 generally rests on the rectangular tubes 1470, 1472 rather than on the wheels 16a, 16b, 22a, 22b.
  • the tires of the front and rear wheels 16a, 16b and 22a, 22b could, in some instances, be deflated without risking damage to the tires on the wheels 16a, 16b and 22a, 22b as they may extend below frame members 1454, 1456.
  • the front and rear suspensions 18 and 24 or 700 also abut suspension stoppers of the ATV 10 (not shown).
  • the ATV 10 can be attached to the bottom frame portion 1460 by connecting a plurality of plastic straps (not shown) or other securing means.
  • the crate 1450 can be closed by assembling the side walls portions 1482, 1484 and the top wall portion 1486 to the bottom frame portion.
  • the side walls portions 1482, 1484 and the top wall portion 1486 can be assembled together first, and then connected to the bottom wall portion 1460, although this may not always be the case.
  • the frame 1452 of the crate 1450 can be wrapped with a plastic material or any other suitable material to protect the ATV 10 during shipment.

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Abstract

An ATV frame comprising a main frame with front and rear portions configured to receive front and rear suspensions respectively, and a middle portion comprising left top, left bottom, right top and right bottom longitudinal members, the distances between the left top and left bottom and between the right top and right bottom longitudinal members being different. The longitudinal members define an engine compartment adapted to receive engines of different sizes, and a space is defined above the top longitudinal member being at a lesser distance from the respective bottom longitudinal member. The rear portion may comprise pivotably mounted transversal arms, and a hitch assembly pivotably mounted to the transversal arms. A rear suspension may comprise swing arms allowing a torsional movement. The front portion may comprise transverse members pivotally connected to a bottom cross-member. Configurations, maintenance, performance and accessibility of service centers, airboxes and radiators of ATVs are improved.

Description

FRAME FOR AN ALL-TERRAIN VEHICLE AND ALL-TERRAIN VEHICLE COMPRISING THE SAME
CROSS-REFERENCE
[0001] The present application claims the benefit of United States Provisional Patent Application serial number 63/446,420 filed on February 17, 2023.
FIELD
[0002] The invention relates to a frame for an all-terrain vehicle (ATV) and to an ATV comprising the same. More particularly, the frame for the ATV is adapted for housing engines having different sizes, and various configurations of rear suspensions. In some embodiments, the ATV is provided with a service center providing access to an airbox allowing service and maintenance of an air filter via the service center, and to a radiator configuration. The invention further relates to steering assembly, gas tank and airbox configurations for an ATV, a hitch assembly and to a method for packaging such an all- terrain vehicle.
BACKGROUND
[0003] All-terrain vehicles (ATVs) are designed to operate in rough, off-road terrains and generally comprise a robust frame mounted on four wheels. Front and rear suspensions are provided between the frame and the wheel for absorbing bumps. An engine is mounted to the frame and is operatively connected to the rear wheels, and in some instances, to the front wheels as well. The front wheels are operatively connected to a steering assembly for steering the ATV, and a straddle seat is mounted to the frame for the operator to sit. Generally, the straddle seat is positioned above the engine such that the rider is located proximal to the longitudinal position of the center of gravity of the ATV, to minimize the impact of the bumps encountered during the operation of the ATV.
[0004] Because of the use for which they are designed, ATVs are subject to relatively high bending and torsional forces, which have to be resisted by their frames. Typical ATV frames, sometimes referred to as “space” or “open structure” frames, have been constructed with sufficient strength and rigidity for ATV applications. However, to provide the necessary strength and rigidity, these frames are generally highly complex or use a significant amount of material. Such typical frame configurations tend to be costly to manufacture and sometimes present the disadvantage of being heavy. [0005] Moreover, these frames generally need to be designed or redesigned according to the size of the engine that will be ultimately installed in the all-train vehicle. Therefore, if a different size of an engine needs to be installed in a frame, such installation is accompanied with adjusting and redesigning certain components of the frame to account for the difference in size of the engine that being installed. Furthermore, the assembly of the other components to the frame, for instance the front and rear suspensions, the steering assembly, air filter, or other compartments provided within the frame can prove to be challenging since they require specified manufacturing sequences. Also, typical ATV frame configurations provide few options in terms modifying the various components such as, for instance, the rear suspension.
[0006] In addition, ATVs are often used for pulling or hauling heavy equipment, camping gear, hunting gear, other farming or forestry equipment or even other all-terrain vehicles. Therefore, it is not uncommon for hitch receivers be installed on all-terrain vehicles. Such installations usually require drilling holes on the frame of the ATV, which may compromise the integrity of the frame. When the frame of the all-terrain vehicles provide holes and weld nuts for installing a hitch receiver, it is not uncommon for such weld nuts and frame holes to be rusted or corroded from being exposed to the elements. In some cases, the edges of the frame holes may be so rusted that the original frame holes are not good for mounting the hitch receiver anymore.
[0007] Further, ATVs are sometimes provided with a compartment or area trivially designated as “service center” in which are regrouped different vehicle components for easy access by a user, such as the fuse box, coolant fluid, power steering fluid and the like. The service center can be provided on various locations on the ATV, including in the hood area, in front of the handlebar. While known ATV service centers provide easy access to some vehicle components, some other ATV elements that require regular maintenance are located outside the service center, for instance the airbox, and require dismantling other portions ofthe ATV such as cowlings and/orthe seat to provide a user with access to those elements for maintenance.
[0008] While on many ATVs the radiator is typically located in front of the front wheels, under a cover that substantially shields the radiator from the elements, the operation of such ATVs in water or in muddy conditions leads to mud and debris to be splashed onto the radiator and cause it to block the air passing through the radiator to cool the engine coolant. In some instances, it was thus envisioned to move the radiator from a more conventional position to a raised position, where the radiator is positioned generally above the front wheel of the ATV, proximate to the handlebar. To protect the radiator, a radiator cover is provided. While this positioning of the radiator contributes to reduce the exposure of the radiator to debris and mud, they are nevertheless prone to clogging, and the maintenance or cleaning of the radiator sometimes requires tools and/or removal of cowlings.
[0009] Accordingly, there is a need for an improve ATV configuration that alleviates at least some of the above-identified drawbacks.
SUMMARY
[0010] According to a broad aspect of the present invention, there is provided a frame for an all-terrain vehicle, the frame comprising a main frame extending along a longitudinal axis and comprising a front portion, a middle portion and a rear portion, the front portion being configured to receive a portion of a front suspension, the rear portion being configured to receive a portion of a rear suspension, and the middle portion comprising: a left bottom longitudinal member extending from a left bottom proximal end portion through a middle portion to a left bottom distal end portion; a right bottom longitudinal member extending from a right bottom proximal end portion through a middle portion to a right bottom distal end portion; a left top longitudinal member extending from a left top proximal end portion through a middle portion to a left top distal end portion; and a right top longitudinal member extending from a right top proximal end portion through a middle portion to a right top distal end portion; a first distance being defined between one of the left top longitudinal member and the left bottom longitudinal member or the right top longitudinal member and the right bottom longitudinal member; a second distance being defined between the other of the left top longitudinal member and the left bottom longitudinal member or the right top longitudinal member and the right bottom longitudinal member, the first and second distances being measured at corresponding left and right positions along the longitudinal axis; the first distance being greater than the second distance; the left and right bottom longitudinal members and the left and right top longitudinal members defining therebetween an engine compartment adapted to receive engines of different sizes; and a space being defined above the other of the left and right top longitudinal members being at the second distance.
[001 1] In one feature, the space is defined between the one of the left and right top longitudinal members being at the first distance and the other of the left and right top longitudinal members being at the second distance.
[0012] In one feature, the first distance is defined between the right top longitudinal member and the right bottom longitudinal member and the second distance is defined between the left top longitudinal member and the left bottom longitudinal member.
[0013] In one feature, the space is defined between the left and right top longitudinal members. In one feature, the space is adapted to receive at least one component of the all-terrain vehicle. In one feature, the at least one component is selected from a group comprising a steering assembly, steering cables, an airbox, an air filter, a storage compartment and a battery.
[0014] In one feature, the middle portion comprises: a front top cross-member extending between the left top distal end portion of the left top longitudinal member and the right top distal end portion of the right top longitudinal member, the front top cross-member comprising left and right end portions, and a left longitudinal member extending outwardly sidewardly from the left end portion of the front top cross-member or from the left top distal end portion of the left top longitudinal member and downwardly to a left bottom end portion, the space being defined above the left top longitudinal member and therebetween the left longitudinal member and the right top longitudinal member.
[0015] In one feature, the middle portion comprises a front left member extending upwardly from the left bottom longitudinal member up to the front top cross-member and a front right member extending upwardly from the right bottom longitudinal member up to the front top cross-member.
[0016] In one feature, the middle portion comprises a right longitudinal member extending outwardly sidewardly from the right proximal end portion of the front top crossmember or from the right top proximal end portion of the right top longitudinal member and downwardly to a right bottom end.
[0017] In one feature, the first distance is between about 65 cm and about 45 cm and the second distance is between about 60 cm and about 40 cm. [0018] In one feature, the middle portion comprises: a first lower cross-member connecting the left bottom longitudinal member and the right bottom longitudinal member at the left and right bottom proximal ends; and a second lower cross-member comprising left and right end portions, and extending between the left bottom longitudinal member and the right bottom longitudinal member at the middle portion of the left and right bottom longitudinal members, the left end portion of the second lower cross-member connecting the front left member extending upwardly and the left bottom longitudinal member, and the right end portion of the second lower cross-member connecting the front right member extending upwardly and the right bottom longitudinal member.
[0019] In one feature, the front top cross-member is a first top cross-member and wherein the middle portion comprises a second top cross-member connecting the first left and right top longitudinal members at respective left and right middle portions of the first left and right top longitudinal members.
[0020] In one feature, the space is defined above the second top cross-member.
[0021 ] In one feature, the middle portion comprises a rear left member extending upwardly from the left bottom distal end portion of the left bottom longitudinal member to the left distal end portion of the left top longitudinal member and a rear right member extending upwardly from the right bottom distal end portion of the right bottom longitudinal member to the right distal end portion of the right top longitudinal member.
[0022] In one feature, the engine compartment is adapted to receive a first engine having a first size or a second engine having a second size without modification of the left and right bottom longitudinal members and of the left and right top longitudinal members, the second size being larger than the first size.
[0023] In one feature, the middle portion comprises a rear left engine mounting bracket, a front left engine mounting bracket, a rear right engine mounting bracket and a front right engine mounting bracket, the rear and front left engine mounting brackets and the rear and front right engine mounting brackets comprising rear and front left connectors and rear and front right connectors for mounting one of the first and second engines to the middle portion.
[0024] In one feature, the front suspension comprises left and right front shock absorbers. In one feature, the rear suspension comprises left and right rear shock absorbers. [0025] According to another broad aspect of the present invention, there is provided a frame for an all-terrain vehicle, the frame comprising a main frame comprising a front portion, a middle portion and a rear portion extending along a longitudinal axis between a rear proximal end and a rear distal end, the rear portion comprising: a left member adjacent the rear proximal end, the left member extending upwardly from a left bottom end portion to a left top end portion, and a right member adjacent the rear proximal end, the right member extending upwardly from a right bottom end portion to a right top end portion; a left transversal arm adjacent the rear proximal end, the left transversal arm extending transversely between a left proximal end portion and a left distal end portion, and a right transversal arm adjacent the rear proximal end, the right transversal arm extending transversely between a right proximal end portion and a right distal end portion, the left and right proximal end portions of the left and right transversal arms being pivotably mounted to the left and right bottom end portions of the left and right members; and a hitch receiver mounted to the left and right proximal end portions of the left and right transversal arms and to the left and right members, the proximal end portions of the left and right transversal arms being sandwiched between the left and right members and the hitch receiver.
[0026] In one feature, the proximal end portions of the left and right transversal arms are pivotably mounted rearwardly of the left and right bottom end portions of the left and right members.
[0027] In one feature, the hitch receiver comprises a central projection extending rearwardly along the longitudinal axis from a distal end portion to a proximal end portion, and left and right protrusions extending transversely from the distal end portion of the central projection, the left and right protrusions of the hitch receiver being mounted to the left and right proximal end portions of the left and right transversal arms and to the left and right members.
[0028] In one feature, the left and right protrusions comprise left and right bottom protrusions extending transversely from the distal end portion, and left and right top protrusions extending transversely from the distal end portion, the left and right bottom protrusions of the hitch receiver being mounted to the left and right proximal end portions of the left and right transversal arms, and the left and right top protrusions of the hitch receiver being mounted to the left and right members.
[0029] In one feature, the hitch receiver comprises a left flange between the left bottom and top protrusions and a right flange between the right bottom and top protrusions. In one feature, the hitch receiver comprises a left bottom flange between the left bottom protrusion and the central projection and a right bottom flange between the right bottom protrusion and the central projection.
[0030] In one feature, the central projection comprises exterior and inner walls and the inner wall defines a housing for receiving an elongated portion of a hitch.
[0031] In one feature, the left and right members comprise left and right rear surfaces and the left and right proximal end portions of the left and right transversal arms are mounted to the left and right rear surfaces.
[0032] In one feature, the left and right proximal end portions of the left and right transversal arms comprise left and right rear surfaces, the left and right bottom protrusions of the hitch receiver are mounted to the left and right rear surfaces of the left and right proximal end portions of the left and right transversal arms, and the left and right top protrusions of the hitch receiver are mounted to the left and right rear surfaces of the left and right members.
[0033] In one feature, the left and right proximal end portions of the left and right transversal arms comprise left and right proximal ends extending longitudinally along left and right bottom mounting axes between the left and right bottom protrusions of the hitch receiver and the left and right members, the left and right proximal ends comprising left and right inner walls extending along the left and right bottom mounting axes and defining left and right housings.
[0034] In one feature, the left and right bottom protrusions comprise left and right bottom apertures at respective distal ends and the left and right top protrusions comprise left and right top apertures at respective distal ends, the left and right bottom apertures being around the left and right bottom mounting axes.
[0035] In one feature, the left and right members comprise left and right top holes and left and right bottom holes, the left and right top holes being aligned with the left and right top apertures, and the left and right bottom holes being around the left and right bottom mounting axes. [0036] In one feature, the frame comprises left and right bottom fasteners mounted in the left and right bottom apertures, in the left and right housings and in the left and right bottom holes, and left and right top fasteners mounted in the left and right top apertures and in the left and right top holes for affixing the hitch receiver to the left and right members.
[0037] In one feature, the frame comprises left and right bushings mounted in the left and right housings and around the left and right bottom fasteners and the left and right proximal ends are pivotably mounted around the left and right bushings and left and right bottom fasteners for allowing pivotable movement of the left and right transversal arms relative to the left and right bottom mounting axes.
[0038] In one feature, the left and right members comprise left and right bottom projections extending forwardly along the left and right bottom mounting axes, the left and right bottom projections comprising left and right inner walls defining left and right bottom channels aligned with the left and right bottom holes.
[0039] In one feature, the left and right members comprise left and right top projections extending forwardly along left and right top mounting axes, the left and right top projections comprising left and right inner walls defining left and right top channels aligned with the left and right top holes.
[0040] In one feature, the left and right bottom fasteners comprise left and right bottom bolts comprising left and right distal threaded ends and left and right bottom nuts, the left and right top fasteners comprise left and right top bolts comprising left and right distal threaded ends and left and right top nuts, the left and right distal threaded ends of the left and right bottom bolts extend forwardly outside the left and right bottom channels, the left and right distal threaded ends of the left and right top bolts extend forwardly outside the left and right top channels, the left and right bottom nuts are mounted to the left and right distal threaded ends of the left and right bottom bolts, and the left and right top nuts are mounted to the left and right distal threaded ends of the left and right top bolts.
[0041] In one feature, the frame comprises a left shock absorber adjacent the rear proximal end, the left shock absorber extending upwardly from a left bottom end portion to a left top end portion, and a right shock absorber adjacent the rear proximal end, the right shock absorber extending upwardly from a right bottom end portion to a right top end portion, the left and right bottom end portions of the left and right shock absorbers being mounted to the left and right transversal arms, and upon pivotal movement of the left and right transversal arms, the left and right shock absorbers are compressed or expanded. [0042] In one feature, the left and right transversal arms are left and right bottom transversal arms, the rear portion of the frame comprises left and right top transversal arms adjacent the rear proximal end, the left and right top transversal arms extend from left and right top proximal ends to left and right top distal ends, the left and right top proximal ends of the left and right top arms are pivotably mounted to the left and right members, and upon pivotal movement of the top and bottom left and right transversal arms, the left and right shock absorbers are compressed or expanded.
[0043] In one feature, the left proximal end of the left transversal arm comprises a left rear external circular wall facing the left bottom protrusion of the hitch receiver, the right proximal end of the right transversal arm comprises a right rear external circular wall facing the right bottom protrusion of the hitch receiver, and the left and right rear circular external walls and the left and right bottom protrusions define left and right rear spaces therebetween.
[0044] According to another broad aspect of the present invention, there is provided an all-terrain vehicle comprising a main frame comprising a front portion, a middle portion and a rear portion extending along a longitudinal axis between a rear proximal end and a rear distal end, the middle portion being configured to receive an engine, the front portion comprising: a left bottom longitudinal member extending from a front left bottom proximal end portion to a front left bottom distal end portion; a right bottom longitudinal member extending from a front right bottom proximal end portion to a front right bottom distal end portion; a first bottom cross-member extending between the left and right bottom longitudinal members and comprising: left and right ends; a proximal and distal surfaces; a first left transversal member adjacent to the left bottom distal end portion, the first left transversal comprising a proximal end and a distal end; and a first right transversal member adjacent to the right bottom distal end portion, the first right transversal member comprising a proximal end and a distal end; the proximal ends of the first left and right transverse members being pivotally connected to the bottom cross-member between the left and right longitudinal members.
[0045] In one feature, each of the first left and right transversal member comprises a front portion having a front distal end and a rear proximal end, and a rear portion having a rear distal end and a rear proximal end, the rear proximal ends of rear portions of the first left and right transverse members being connected to the bottom cross-member between the left and right longitudinal members.
[0046] In one feature, the first left transversal member is pivotably mounted on a left axe provided at the proximal surface of first bottom cross-member, and the first right transversal member is pivotably mounted on a right axe provided at the proximal surface of the first bottom cross-member.
[0047] In one feature, the first left transversal member extends slightly upwardly and away from the bottom cross-member passing overthe front left bottom longitudinal member and to a left a knuckle for mounting a left wheel; and the first right transversal member extends slightly upwardly and away from the bottom cross-member passing over the front right bottom longitudinal member and to a right knuckle for mounting a right wheel.
[0048] In one feature, the all-terrain vehicle comprises a second bottom cross-member sandwiching the first left and right transversal members between the first bottom crossmember, the second bottom cross-member securely fastening the first left and right transversal members, while allowing pivotal movement of the first left and right transversal members.
[0049] In one feature, the front portion comprises a left and right bottom fasteners mounted in first and second holes of the first bottom cross-member, and the left and right bottom fasteners comprise left and right bottom bolts comprising left and right distal threaded ends, the left and right mounting axes, and left and right bottom nuts, the left and right distal threaded ends of the left and right bottom bolts extending forwardly through the first and second holes, and outside of the first cross-member, and the second bottom crossmember being mounted on the left and right distal threaded ends.
[0050] In one feature, the front portion comprises a left member extending upwardly from the left bottom distal end portion to a left top end portion; a right member extending upwardly from the right bottom distal end portion to a right top end portion; and a top crossmember extending between the left and right top ends.
[0051 ] In one feature, the front portion comprises a middle cross-member above the first bottom cross-member, and extending between the left and right members, the middle cross-member comprising a mounting bracket for mounting a second left and right transversal members, the second left transversal member being pivotably mounted to the mounting bracket and extending away from the middle cross-member passing over the front left bottom longitudinal member and to the left knuckle, and the second right transversal member being pivotably mounted to the mounting bracket and extending away from the middle cross-member passing over the front right bottom longitudinal member and to the right knuckle.
[0052] In one feature, the front portion comprises left and right shock absorbers extending upwardly from their respective left and right second left and right transversal members to the top cross-member, the left and right shock absorbers being pivotably mounted to the top cross-member, and upon pivotal movement of the first and second left and right transversal members, the left and right shock absorbers are compressed or expanded.
[0053] According to another broad aspect of the present invention, there is provided a rear suspension for an all-terrain vehicle including a main frame, the rear suspension comprising: a main swing arm including a left portion and a right portion, each of the left and right portions including a front end for pivotably mounting the main swing arm to the main frame of the all-terrain vehicle and a rear end, each of the left and right portions being configured to allow a torsional movement along a longitudinal axis of the left and right portions; a drive axle mounted to the rear end of the left and right portions; and at least one shock absorber having a first end mounted to the main swing arm and a second end mountable to the main frame of the all-terrain vehicle.
[0054] In one feature, the main frame of the vehicle comprises left and right brackets, and the front ends of the left and right portions of the main swing arm are respectively pivotably mounted to the left and right brackets. [0055] In one feature, the at least one shock absorber comprises a left shock absorber and a right shock absorber.
[0056] In one feature, the first end of the left shock absorber is mounted proximal to the rear end of the left portion of the main swing arm and the first end of the right shock absorber is mounted proximal to rear end of the right portion of the main swing arm.
[0057] In one feature, the rear suspension further comprises a differential operatively coupled to the drive axle.
[0058] In one feature, each of the left and right portions of the main swing arm comprise a front portion extending from the font end of to an intermediate location and rear portion extending from the intermediate location to the rear end.
[0059] In one feature, the rear portion is generally T-shaped.
[0060] In one feature, the drive axle comprises a sleeve portion, and wherein rear end of the rear portion is attached to the sleeve portion. In one feature, the rear end of the rear portion is welded to the sleeve portion.
[0061] In one feature, the drive axle further comprises a shaft member rotatably received in the sleeve portion.
[0062] In one feature, the front portion comprises a generally cylindrical tube extending from the front end to the intermediate location.
[0063] In one feature, the front end of the front portion comprises a recess extending transverse to the longitudinal axis of the cylindrical tube, the recess being configured for receiving a bushing therein for securing the front portion to a corresponding bracket of the lower left tube of the main frame.
[0064] In one feature, the bushing allows the corresponding left or right portion to pivot about a pivot axis P-P and a torsion movement about an axis LT-LT of the corresponding left or right portion relative to the bracket to which it is attached without compromising the pivoting movement about axis P-P.
[0065] In one feature, the front and rear portions are two discrete components attached to one another. In one feature, the front and rear portions are attached to one another by welding. In one feature, the front and rear portions are attached to one another using nuts, bolts, brackets or collars. In one feature, the front and rear portions of the left portion are manufactured as a single piece.
[0066] In one feature, the rear portion has a generally oblong cross-section. In one feature, the rear portion is sized, shaped and made of a material allowing a limited torsion of the rear portion about a longitudinal axis LT-LT.
[0067] In one feature, at least one of the front portion and rear portion is made of Strenx™ 700 structural steel. In one feature, the Strenx™ 700 structural steel has a thickness of about 0.0551 inch (1 .4 mm).
[0068] According to another broad aspect of the present invention, there is provided an all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steer the front wheels of the all-terrain vehicle, the all-terrain vehicle comprising: a front end; a rear end; a service center compartment for providing a user with an access to at least one component of the all-terrain vehicle for maintenance thereof; and a service center cover for removably closing said service center compartment, the service center comprising an air entry into an airbox; the service center cover being located in front of the steering device.
[0069] In one feature, the steering device comprises a handlebar.
[0070] In one feature, the at least one component of the all-terrain vehicle is selected from a group comprising a portion of an airbox, a coolant bottle, a fuse box and a CVT air entry.
[0071] In one feature, the service center cover is configured for easy removal. In one feature, the service center cover is removably securable to the service center compartment. In one feature, the service center cover is removably securable to the service center compartment using at least one of a toolless % turn, a toe-in, a snap engagement means, a hoop and loop fastener or a magnet. [0072] In one feature, the service center cover comprises at least one electrical component. In one feature, the at least one electrical component is selected from a group comprising a display for displaying information concerning systems of the all-terrain vehicle, a communication device to the driver and an electric outlet.
[0073] In one feature, the all-terrain vehicle further comprises at least one wire extending from service center compartment and connectable to the service center cover for supplying the at least one electrical component with electric power or data. In one feature, the at least one wire comprises such a length as to allow the service center cover to be removed from the service center compartment and placed to one side thereof to allow access the at least one component within the service center compartment without having to disconnect the at least one wire. In one feature, the at least one wire is detachably connectable to at least one of the service center compartment and the service center cover.
[0074] In one feature, the airbox comprises an airbox body provided with an airbox opening and defining an airbox compartment, an airbox cover removably mounted to the airbox body for closing the airbox opening, an air inlet allowing airto enterthe airbox body, an air outlet for allowing air to exit the airbox housing to reach an engine of the all-terrain vehicle and an air filter removably received into the airbox body through the airbox opening for filtering the air between the air inlet and the air outlet, the airbox opening and the airbox cover being located in the service center compartment and allowing for the air filter to be removed or installed via access to the service center compartment.
[0075] According to another broad aspect of the present invention, there is provided an all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steer the front wheels of the all-terrain vehicle, the all-terrain vehicle comprising: a front end; a rear end; an airbox comprising an airbox body provided with an airbox opening and defining an airbox compartment; an airbox cover removably mounted to the airbox body for closing the airbox opening; an air inlet allowing air to enter the airbox body; an air outlet for allowing air to exit the airbox housing to reach an engine of the all- terrain vehicle; and an air filter removably received into the airbox body through the airbox opening for filtering the air between the air inlet and the air outlet, the airbox opening and the airbox cover being in front of the steering device.
[0076] In one feature, the steering device comprises a handlebar.
[0077] In one feature, the all-terrain vehicle further comprises a service center compartment for providing a user with an access to at least one component of the all- terrain vehicle for maintenance thereof; and a service center cover for removably closing said service center compartment, the service center cover being located in front of the steering device, the airbox opening and the airbox cover located in the service center compartment being accessible to a user when the service center cover is removed.
[0078] In one feature, the airbox body comprises a top portion and a bottom portion, the top portion being configured to receive the air inlet. In one feature, the top portion further comprises the airbox opening.
[0079] In one feature, the airbox cover is configured to abut the airbox opening and to be removably secured to the airbox body.
[0080] In one feature, the airbox cover is secured to the airbox body and held in place using securing devices configured to be manipulated and removed without the use of tools. In one feature, the securing devices comprise one or more over-center clips.
[0081] In one feature, the airbox cover comprises at least one protrusion extending into the airbox body when the airbox cover is secured to the airbox body, the at least one protrusion holding the air filter in an installed position. In one feature, the at least one protrusion extends substantially vertically. In one feature, the at least one protrusion comprises at least one of a notch, a recess or an indentation for receiving therein a portion of the air filter to hold the air filter in the installed position.
[0082] In one feature, the airbox further comprises a Helmholtz resonator received in the airbox body.
[0083] According to another broad aspect of the present invention, there is provided an all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steer the front wheels of the all-terrain vehicle, the all-terrain vehicle comprising: a front end; a rear end; a radiator mounted in front of the steering device and above the front wheels; a radiator cover for substantially covering the radiator, the radiator cover comprising: a pair of spaced-apart side covers extending generally vertically on each side of the radiator; a top cover extending between the spaced apart side covers and generally parallel to the radiator, the top cover being pivotably attached to one of the radiator and the spaced-apart side covers; an air opening defined on a front end of the radiator cover, the spaced-apart side covers and the top cover of the radiator cover contributing to generate a ram air effect of the air entering the air opening inside the radiator cover for ramming oncoming air onto the radiator during operation of the all-terrain vehicle.
[0084] In one feature, the radiator extends at a rearward angle between the front end of the all-terrain vehicle and the rear end thereof.
[0085] In one feature, the rearward angle of the radiator varies between 30 and 60 degrees relative to a horizontal plane.
[0086] In one feature, the spaced-apart side covers extend substantially vertically along a longitudinal axis of the all-terrain vehicle.
[0087] In one feature, the all-terrain vehicle further comprises a pair of wheel fenders for covering the front wheels of the all-terrain vehicle, wherein each of the spaced-apart sides covers extend vertically from a corresponding wheel fender.
[0088] In one feature, the top cover comprises a front end and a rear end, wherein the front end of the top cover is pivotably attached to the spaced-apart side covers. [0089] In one feature, the radiator cover further comprises at least one latching device for securing the top cover to the spaced-apart side covers and maintain the top cover in a closed position.
[0090] In one feature, the radiator further comprises a removable toolkit. In one feature, the removable toolkit is removably securable to an inner face of the top cover.
[0091] These and other aspects of the invention will now become apparent to those of ordinary skill in the art upon review of the following description of embodiments of the invention in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0092] Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration example embodiments thereof and in which:
[0093] Figure 1 is a rear, right perspective view of an ATV, in accordance with one embodiment of the present invention;
[0094] Figure 2 is a rear left perspective view the ATV shown in Figure 1 ;
[0095] Figure 3 is a front left perspective view of the ATV shown in Figure 1 ;
[0096] Figure 4 is a front right perspective view of the ATV shown in Figure 1 ;
[0097] Figure 5 is a left-side view of the ATV shown in Figure 1 ;
[0098] Figure 6 is a right-side view of the ATV shown in Figure 1 ;
[0099] Figure 7 is a front elevation view of the ATV shown in Figure 1 ;
[00100] Figure 8 is a rear elevation view of the ATV shown in Figure 1 ;
[00101] Figure 9 is a top plan view of the ATV shown in Figure 1 ;
[00102] Figure 10 is a rear right perspective view of a main frame for an ATV with a front bumper assembly and a front suspension attached thereto, in accordance with one embodiment;
[00103] Figure 11 is a left-side view of the main frame, front bumper assembly and front suspension shown in Figure 10; [00104] Figure 12 is a left-side view of the main frame, front bumper assembly and front suspension shown in Figure 10;
[00105] Figure 13 is a top plan view of the main frame, front bumper assembly and front suspension shown in Figure 10;
[00106] Figure 14 is a bottom plan view of the main frame, front bumper assembly and front suspension shown in Figure 10;
[00107] Figure 15 is a front elevation view of the main frame, front bumper assembly and front suspension shown in Figure 10;
[00108] Figure 16 is a rear elevation view of the main frame, front bumper assembly and front suspension shown in Figure 10;
[00109] Figure 17 is a front, left perspective view of the main frame, front bumper assembly and front suspension shown in Figure 10, with the front suspension attached thereto and the front bumper assembly detached therefrom;
[00110] Figure 18 is a rear right perspective view of the main frame, front suspension and front bumper assembly shown in Figure 17;
[00111] Figure 19 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 17;
[00112] Figure 20 is a right-side view of the main frame, front suspension and front bumper assembly shown in Figure 17;
[00113] Figure 21 is a top plan view of the main frame, front suspension and front bumper assembly shown in Figure 17;
[00114] Figure 22 is a bottom plan view of the main frame, front suspension and front bumper assembly shown in Figure 17;
[00115] Figure 23 is a rear right perspective view of a main frame for an ATV with a front bumper assembly and a front suspension attached thereto, in accordance with another embodiment;
[00116] Figure 24 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 23; [001 17] Figure 25 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 23;
[001 18] Figure 26 is a top plan view of the main frame, front suspension and front bumper assembly shown in Figure 23;
[001 19] Figure 27 is a bottom plan view of the main frame, front suspension and front bumper assembly shown Figure 23;
[00120] Figure 28 is a front elevation view of the main frame, front suspension and front bumper assembly shown in Figure 23;
[00121] Figure 29 is a rear elevation view of the main frame, front suspension and front bumper assembly shown in Figure 23;
[00122] Figure 30 is a front, left perspective view of the main frame, front suspension and front bumper assembly shown in Figure 23;
[00123] Figure 31 is a front, left perspective view of the main frame, front suspension and front bumper assembly shown in Figure 23, with the front suspension attached thereto and the front bumper assembly detached therefrom;
[00124] Figure 32 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 31 ;
[00125] Figure 33 is a right-side view of the main frame, front suspension and front bumper assembly shown in Figure 31 ;
[00126] Figure 34 is a top plan view of the main frame, front suspension and front bumper assembly shown in Figure 31 ;
[00127] Figure 35 is a rear right perspective view of view of a main frame for an ATV with a front bumper assembly and a front suspension attached thereto, in accordance with another embodiment;
[00128] Figure 36 is a left-side view of the frame, front bumper assembly and front suspension shown in Figure 35;
[00129] Figure 37 is a left-side view of the main frame, front bumper assembly and front suspension shown in Figure 35; [00130] Figure 38 is a top plan view of the main frame, front bumper assembly and front suspension shown in Figure 35;
[00131] Figure 39 is a bottom plan view of the main frame, front bumper assembly and front suspension shown in Figure 35;
[00132] Figure 40 is a front elevation view of the main frame, front bumper assembly and front suspension shown in Figure 35;
[00133] Figure 41 is a rear elevation view of the main frame, front bumper assembly and front suspension shown in Figure 35;
[00134] Figure 42 is a front, left perspective view of the main frame, front bumper assembly and front suspension shown in Figure 35;
[00135] Figure 43 is a front, left perspective view of the main frame, front suspension and front bumper assembly shown in Figure 35, with the front suspension attached thereto and the front bumper assembly detached therefrom;
[00136] Figure 44 is a left-side view of the main frame, front suspension and front bumper assembly shown in Figure 43;
[00137] Figure 45 is a right-side view of the main frame, front suspension and front bumper assembly shown in Figure 43;
[00138] Figure 46 is a top plan view of the main frame, front suspension and front bumper assembly shown in Figure 43;
[00139] Figure 47 is a front, right perspective view of a main frame for an ATV, in accordance with another embodiment;
[00140] Figure 48 is a right-side view of the main frame shown in Figure 47;
[00141] Figure 49 is a left-side view of the main frame shown in Figure 47;
[00142] Figure 50 is a top plan view of the main frame shown in Figure 47;
[00143] Figure 51 is a top plan view of the main frame shown in Figure 47, along with an engine and a gas tank, in accordance with one embodiment; [00144] Figure 52A is a front right perspective view of an engine for an ATV, in accordance with one embodiment;
[00145] Figure 52B is a front right perspective view of an engine for an ATV, in accordance with another embodiment;
[00146] Figure 53 is a front right perspective view of the main frame shown in Figure 47 provided with engine mounting brackets for mounting the engine shown in Figure 52A into the engine compartment, in accordance with one embodiment;
[00147] Figure 54 is a front right perspective view of the frame shown in Figure 47 provided with engine mounting brackets for mounting the engine shown in Figure 52B into the engine compartment, in accordance with one embodiment;
[00148] Figure 55 is a rear right, exploded perspective view of the frame shown in Figure
53 with the engine shown in Figure 52A and an airbox, in accordance with one embodiment;
[00149] Figure 56 is a rear right perspective view of the frame shown in Figure 53, with the engine shown in Figure 52A mounted into the engine compartment and the airbox mounted in a space located above the engine compartment, in accordance with one embodiment;
[00150] Figure 57 is a rear right, exploded perspective view of the frame shown in Figure
54 with the engine shown in Figure 52B and an airbox, in accordance with one embodiment;
[00151] Figure 58 is a rear right perspective view of the frame shown in Figure 54, with the engine shown in Figure 52B mounted into the engine compartment and the airbox mounted in a space located above the engine compartment, in accordance with one embodiment;
[00152] Figure 59 is a rear right perspective view of a front suspension for an ATV, in accordance with one embodiment;
[00153] Figure 60 is a top plan view of the front suspension shown in Figure 59;
[00154] Figure 61 is a front elevation view of the front suspension shown in Figure 59;
[00155] Figure 62 is a left-side view of the front suspension shown in Figure 59; [00156] Figure 63 is an exploded view of an A-arm assembly for a front suspension of an ATV, in accordance with one embodiment;
[00157] Figure 64 is a rear right perspective view of a main frame for an ATV, with a front bumper assembly, a front suspension and a main swing arm of a rear suspension attached thereto, in accordance with one embodiment;
[00158] Figure 65 is a front left perspective view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
[00159] Figure 66 is a left-side view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
[00160] Figure 67 is a right-side view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
[00161] Figure 68 is a rear elevation view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
[00162] Figure 69 is a bottom view of the main frame, front bumper assembly, front suspension and the main swing arm of the rear suspension shown in Figure 64;
[00163] Figure 70 is an exploded view of a main swing arm of a rear suspension, in accordance with one embodiment of the present invention;
[00164] Figure 71 is a front left perspective view of the main swing arm shown in Figure 70, with rear shock absorbers and rear coil springs attached thereto, in accordance with one embodiment;
[00165] Figure 72 is a top plan view of the main swing arm, the rear shock absorbers and the rear coil springs shown in Figure 71 , with the rear wheels attached thereto, in accordance with one embodiment;
[00166] Figure 73 is a left-side view of the main swing arm, the rear shock absorbers and the rear coil springs and wheels shown in Figure 72;
[00167] Figure 74 is a rear right perspective view of a main frame for an ATV, with a front bumper assembly partially detached therefrom, and a main swing arm of the rear suspension in a full-bump position, an exhaust system and a gas tank attached thereto, in accordance with one embodiment;
[00168] Figure 75 is a top plan view of the main frame, front bumper assembly, main swing arm of the rear suspension, exhaust system and gas tank shown in Figure 74;
[00169] Figure 76 is a bottom plan view of the main frame, front bumper assembly, main swing arm of the rear suspension, exhaust system and gas tank shown in Figure 74;
[00170] Figure 77 is a rear elevation view of the main frame, front bumper assembly, main swing arm of the rear suspension, exhaust system and gas tank shown in Figure 74;
[00171] Figure 78 is a rear right perspective view of a main frame for an ATV, with a front bumper assembly detached therefrom, and a rear suspension, an exhaust system and a gas tank attached thereto, in accordance with another embodiment;
[00172] Figure 79 is a left-side view of the main frame, front bumper assembly, rear suspension, exhaust system and gas tank shown in Figure 78;
[00173] Figure 80 is a bottom view of the main frame, front bumper assembly, rear suspension, exhaust system and gas tank shown in Figure 78, showing a longitudinal axis Li -Li , in accordance with one embodiment;
[00174] Figure 81 is a rear elevation view of the main frame, front bumper assembly, rear suspension, exhaust system and gas tank shown Figure 80;
[00175] Figure 82 is a front right perspective view of a rear suspension system for an ATV, in accordance with one embodiment;
[00176] Figure 83 is an exploded view of a main swing arm of the rear suspension system shown in Figure 82, in accordance with one embodiment of the present invention;
[00177] Figure 84 is cross-section view of the main swing arm shown in Figure 83, with rear shock absorbers and rear coil springs attached thereto;
[00178] Figure 85 is a right side elevation view of a gas tank for an ATV, in accordance with one embodiment;
[00179] Figure 86 is a front elevation view of the gas tank shown in Figure 85;
[00180] Figure 87 is a rear elevation view of the gas tank shown in Figure 85; [00181] Figure 88 is a rear, right perspective view of the gas tank shown in Figure 85;
[00182] Figure 89 is a top plan view of the gas tank shown in Figure 85;
[00183] Figure 90 is a bottom plan view of the gas tank shown in Figure 85;
[00184] Figure 91 is a left-side view of the gas tank shown in Figure 85;
[00185] Figure 92 is a rear left perspective view of an engine, a muffler and a gas tank for an ATV, in accordance with one embodiment;
[00186] Figure 93 is a right-side view of the engine, a muffler and gas tank shown in Figure 92;
[00187] Figure 94 is a bottom plan view of the engine, a muffler and gas tank shown in Figure 92;
[00188] Figure 95 is top plan view of the engine, a muffler and gas tank shown in Figure 92;
[00189] Figure 96 is left side view of the gas tank sown in Figure 92 mounted to a main frame of an ATV, in accordance with one embodiment;
[00190] Figure 97 is a rear, left perspective view of the main frame shown in Figure 10, with an alternate embodiment of a rear suspension attached thereto;
[00191] Figure 98 is a rear, left, partially exploded view of the main frame and rear suspension shown in Figure 97;
[00192] Figure 99 is a rear, right, view of the main frame and rear suspension shown in Figure 97;
[00193] Figure 100 is a rear, right, partially exploded view of the main frame and rear suspension shown in Figure 97;
[00194] Figure 101 is a left-side view of the main frame and rear suspension shown in Figure 97;
[00195] Figure 102 is a left side, partially exploded view of the main frame and rear suspension shown in Figure 97; [00196] Figure 103 is a rear right perspective view of a rear suspension subframe, in accordance with one embodiment of the present invention;
[00197] Figure 104 is a rear left perspective view of the rear suspension subframe shown in Figure 103;
[00198] Figure 105 is a top plan view of the rear suspension subframe shown in Figure 103;
[00199] Figure 106 is a left-side view of the rear suspension subframe shown in Figure 103;
[00200] Figure 107 is a rear elevation view of the rear suspension subframe shown in Figure 103;
[00201] Figure 108 is a front elevation view of the rear suspension subframe shown in Figure 103;
[00202] Figure 109 is a top plan view of a rear left suspension for an ATV, in accordance with one embodiment;
[00203] Figure 110 is a bottom plan view of the rear left suspension shown in Figure 109;
[00204] Figure 11 1 is an enlarged rear, left, partially exploded view of the rear suspension subframe shown in Figure 103 and the rear left suspension shown in Figure 109;
[00205] Figure 112 is an enlarged left, partially exploded side view of the rear portion of the main frame, the rear suspension subframe shown in Figure 102;
[00206] Figure 113 is a rear right perspective view of a main frame for an ATV, with a portion of a front bumper assembly, a rear the rear suspension in a showroom configuration, and a partially exploded hitch assembly attached thereto, in accordance with one embodiment;
[00207] Figure 114 is a rear right perspective view of a portion of the main frame, a portion of the rear suspension in a showroom configuration and the hitch assembly shown in Figure 113, with a hitch positioned in a hitch receiver, in accordance with one embodiment; [00208] Figure 115 is a perspective view of the frame shown in Figure 114, with the portion of the rear suspension shown in a full-bump configuration;
[00209] Figure 116 is a rear elevation view of the frame as shown in Figure 114;
[00210] Figure 117 is a rear elevation view of the frame as shown in Figure 115;
[00211] Figure 118 is a rear right perspective view of a rear portion of the main frame, the rear suspension and the hitch assembly shown in Figure 113, with the hitch assembly partially exploded;
[00212] Figure 119 is a partial enlarged view of the main frame, the rear suspension and the hitch assembly shown in Figure 118;
[00213] Figure 120 is another rear right perspective view of a rear portion of the main frame, the rear suspension and the hitch assembly shown in Figure 113, with the hitch assembly partially exploded;
[00214] Figure 121 is another partial enlarged view of the main frame, the rear suspension and the hitch assembly shown in Figure 118;
[00215] Figure 122 is a right-side view of a rear portion of the main frame and hitch assembly shown in Figure 113, with a right proximal end of the rear portion of the main frame shown in cross-section;
[00216] Figure 122A is an enlarged, cross-sectional view ofthe right proximal end of the rear portion of the main frame as shown in Figure 122;
[00217] Figure 123 is a bottom plan view of the rear portion of the frame as shown in Figure 114;
[00218] Figure 124 is a bottom, exploded view a portion of the proximal end of the main frame shown in Figure 113;
[00219] Figure 125 is a left-side view of the main frame, a portion of a front left suspension and of a steering assembly, in accordance with one embodiment, with the steering assembly in a full left steer position and the front left suspension in a showroom position; [00220] Figure 126 is a rear right perspective view of a steering assembly and a portion of the front left suspension, in accordance with one embodiment, with the steering assembly in a full-left steer position and the front left suspension in a showroom position;
[00221] Figure 127 is a right-side view of a steering assembly and a portion of the main frame, in accordance with one embodiment;
[00222] Figure 128 is an enlarged partial right exploded view of the steering assembly shown in Figure 127 and a portion of the front left suspension, in accordance with one embodiment;
[00223] Figure 129 is an enlarged perspective view of the steering assembly and a portion of the front left suspension shown in Figure 126;
[00224] Figure 130 is a bottom plan view of a portion of the steering assembly, a portion of the main frame and a portion of the front suspension in accordance with one embodiment, with the steering assembly in a full left steer position and the suspension in a showroom position;
[00225] Figure 131 is an enlarged perspective view of the steering assembly and a portion of the front left suspension in accordance with one embodiment, with the steering assembly in a full-left steer position and the front left suspension in a full-droop position;
[00226] Figure 132 is another perspective view of the steering assembly and a portion of the front left suspension shown in Figure 131 , with the steering assembly in a full-left steer position and the front left suspension in a full-droop position;
[00227] Figure 133 is a bottom plan view of a portion of the steering assembly, a portion of the main frame and a portion of the front suspension in accordance with one embodiment, with the steering assembly in a full left steer position and the suspension in a full-droop position;
[00228] Figure 134 is a rear, left, exploded view of a portion of the steering assembly and of a portion of the main frame, in accordance with one embodiment of the present invention;
[00229] Figure 135 is a left-side view of a main frame and of an airbox attached thereto, in accordance with one embodiment; [00230] Figure 136 is a rear right perspective view of the main frame and airbox shown in Figure 135;
[00231] Figure 137 is a top plan view of the main frame and airbox shown in Figure 135;
[00232] Figure 138 is a rear right perspective, exploded view of an airbox, in accordance with one embodiment;
[00233] Figure 139 is a rear, exploded view of the airbox shown in Figure 138;
[00234] Figure 140 is a top plan view of the airbox shown in Figure 138;
[00235] Figure 141 is a bottom plan view of the airbox shown in Figure 138;
[00236] Figure 142 is a front, exploded view of the airbox shown in Figure 138;
[00237] Figure 143 is a front left perspective view of an ATV comprising a service center and airbox, in accordance with one embodiment;
[00238] Figure 144 is a left-side view of the ATV shown in Figure 143;
[00239] Figure 145 is the ATV of Figure 144 with a service center cover removed, in accordance with one embodiment;
[00240] Figure 146 is a partial, enlarged top view of a portion ofthe ATV shown in Figure 143 with the service center cover removed, for better showing the service center and airbox configurations, in accordance with one embodiment;
[00241] Figure 147 is a front right perspective view of the service center and airbox shown in Figure 146;
[00242] Figure 148 is a front left perspective view of engine components, a handlebar and a seat of the ATV of Figure 143, in accordance with one embodiment;
[00243] Figure 149 is a front right perspective view of the engine components, the handlebar and the seat shown in Figure 148;
[00244] Figure 150 is a left-side view of an airbox for an ATV, in accordance with one embodiment;
[00245] Figure 151 is a right-side view of the airbox shown in Figure 150; [00246] Figure 152 is a top view of the airbox shown in Figure 150;
[00247] Figure 153 is a front view of the airbox shown in Figure 150;
[00248] Figure 154 is a partially exploded, left side view of the airbox shown in Figure 150, for better showing an airbox cover in a removed position;
[00249] Figure 155 is an exploded left side view of the airbox shown in Figure 150;
[00250] Figure 156 is a left a cross-section across the airbox shown in Figure 153, taken along line 156-156, with an air filter installed;
[00251] Figure 157 is a right a cross-section of the airbox shown in Figure 150 mounted in an ATC, with the airbox cover removed and the air filter installed;
[00252] Figure 158 is a cross-section view of the airbox shown in Figure 157, with the airbox cover removed and the air filter in the process of being removed;
[00253] Figure 159 is a left-side view of the ATV shown in Figure 145, with the air filter removed via access to the service center;
[00254] Figure 160 is a front left perspective view of an ATV, in accordance with another embodiment;
[00255] Figure 161 is a partial, enlarged view of the ATV shown in Figure 160, for better showing a radiator cover, in accordance with one embodiment;
[00256] Figure 162 is a partial, enlarged top view of the ATV shown in Figure 160, for better showing the radiator cover;
[00257] Figure 163 is a front left perspective view of the ATV shown in Figure 160, with the radiator cover in an open position;
[00258] Figure 164 is a partial, enlarged front perspective view of the ATV shown in Figure 163, for better showing features of the radiator cover in open position;
[00259] Figure 165 is a left-side view of the ATV shown in Figure 163;
[00260] Figure 166 is a top view of the ATV shown in Figure 163;
[00261] Figure 167 is a front right perspective view a radiator cover for an ATV, in accordance with one embodiment; [00262] Figure 168 is a bottom view of the radiator cover shown in Figure 167 and a toolkit secured to an inside face of the cover, in accordance with one embodiment;
[00263] Figure 169 is another bottom view of the radiator cover shown in Figure 167, with the toolkit removed from the inside face;
[00264] Figure 170 is a left-side view of a radiator, portion of a radiator cover, an engine, certain engine components and a seat of an ATV in accordance with one embodiment, showing a flow of air relative to the radiator and radiator cover;
[00265] Figure 171 is a top view of the radiator, the portion of a radiator cover, the engine, certain engine components and the seat shown in Figure 170;
[00266] Figure 172 is a left-side view of an ATV in a packing configuration in a crate, in accordance with one embodiment; and
[00267] Figure 173 is a front elevation view of the ATV in the packing configuration shown in Figure 172.
DETAILED DESCRIPTION OF EMBODIMENTS
[00268] In the following description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several reference numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional and are given for exemplification purposes only.
[00269] Moreover, it will be appreciated that positional descriptions such as "above", "below", "forward", "rearward", "left", "right" and the like should, unless otherwise indicated, be taken in the context of the figures only and should not be considered limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional suitable items. Unless specified or limited otherwise, the terms "mounted," "connected," "supported," and "coupled" and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings and are thus intended to include direct connections between two members without any other members interposed therebetween and indirect connections between members in which one or more other members are interposed therebetween. Further, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings. Additionally, the words "lower", "upper", "upward", "down" and "downward" designate directions in the drawings to which reference is made.
[00270] To provide a more concise description, some of the quantitative expressions given herein may be qualified with the term "about". It is understood that whether the term "about" is used explicitly or not, every quantity given herein is meant to refer to an actual given value, and it is also meant to refer to the approximation to such given value that would reasonably be inferred based on the ordinary skill in the art, including approximations due to the experimental and/or measurement conditions for such given value.
[00271] It is to be understood that the phraseology and terminology employed herein are not to be construed as limiting and are for descriptive purpose only. The principles and uses of the teachings of the present disclosure may be better understood with reference to the accompanying description, figures and examples. It is to be understood that the details set forth herein do not construe a limitation to an application of the disclosure.
[00272] Furthermore, it is to be understood that where the claims or specification refer to "a" or "an" element, such reference is not to be construed that there is only one of that element. It is to be understood that where the specification states that a component, feature, structure, or characteristic "may", "might", "can" or "could" be included, that particular component, feature, structure, or characteristic is not required to be included.
[00273] Variants, examples and preferred embodiments of the invention are described hereinbelow.
A TV
[00274] With reference to Figures 1 to 9, an ATV 10 will be described in accordance with one embodiment. In this embodiment, the ATV 10 comprises a main frame 12, an engine 14 (see Figures 5 and 6) mounted to the main frame 12, a front bumper assembly 13, a pair of front wheels 16a, 16b mounted to the main frame 12 via a front suspension 18 and operatively connected to the engine 14 via a front transmission 20 (Figures 3 and 4), and a pair of rear wheels 22a, 22b mounted to the main frame 12 via a rear suspension 24 and operatively connected to the engine 14 via a rear transmission 26 (Figures 2 and 8). The ATV 10 also comprises a steering assembly 28 mounted to the frame 12 and operatively connected to the front wheels 16a, 16b of the ATV 10 for allowing a user to steer the ATV 10, as well as a seat 30 and left and right footrests 32a, 32b (Figures 1 to 6 and 9) for allowing the user to sit on the ATV 10. Provided on the steering assembly 28 are controls (e.g. as seen on Figure 1 , throttle control 29 and brake lever 31). Still in Figure 1 , adjacent to the right footrests 32b, is a rear brake control 33.
Main Frame
[00275] Turning now to Figures 10 to 15, the main frame 12 of the ATV will now be described. In the embodiment shown in Figures 10 to 12, the main frame 12 includes a pair of longitudinally extending, left and right lower tubes 100,102 defining the lower portion of the main frame, as well as a left, generally Y-shaped tube 104 and a right upper tube 106. Forthe purpose of the describing this and other embodiments, the longitudinally extending left and right lower tubes 100, 102 and the longitudinally extending left and right upper tubes 104, 106 will sometimes be referred to as “bottom longitudinal members” 100, 102 or “top longitudinal members” 104, 106, being understood that the terms “lower tubes” and “upper tubes” are used interchangeably with “bottom longitudinal members” and “top longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
[00276] As best shown in Figure 11 , connecting the left lowertube 100 and the left upper tube 104, are front and rear, left upwardly extending tubes 108, 1 10. Likewise, and as best shown in Figure 12, connecting the right lower tube 102 and the right upper tube 106 are front and rear right upwardly extending tubes 112, 114. Extending between the lowertubes 100 and 102 is a plurality of lower cross-members 116a-1 16d (best shown in Figure 14), while upper tubes 104, 106 are connected by upper cross-members 118a-118c (best shown in Figure 13). Likewise, and returning to Figure 10, the front upwardly extending tubes 108 and 112 are connected to one another via cross-members 1 19a, 119b. Together, lower tubes 100, 102, upper tubes 104, 106, front and rear upwardly extending tubes 108, 1 10, 112, 114 and cross-members 116a-116d, 118a-118c and 119a-119b define a frame engine compartment or housing 120 (see Figures 10 to 12) for receiving the engine 14 of the ATV 10, as well as a portion of the front and/or rear transmissions 20, 26, as it will be described in greater detail below. As it will be understood by the person skilled in the art, the term “engine compartment” is used to broadly define an area or space in which the engine of the ATV can be received. As such, this term should be interpreted to include any engine cradle, engine bay, engine housing or any other term that is used to designate such an area for receiving an engine in an ATV. [00277] The person skilled in the art will also appreciate that brackets, bushings, rubber, support plates, bolts and the like can be used to secure the engine 14 to main frame 12 while reducing vibrations caused by the operation of engine 14.
[00278] As best shown in Figures 10 to 12, the right top longitudinal member 106 is at a first distance di from the right bottom longitudinal member 102 and the left top longitudinal member 104 is at a second distance from the left bottom longitudinal member 100. It is understood that the first and second distances di and d2 are measured at corresponding left and right positions along the longitudinal axis. In the illustrated embodiment, the first distance di is greater than the second distance d2 and the left and right bottom longitudinal members 100, 102 and the left and right top longitudinal members 104, 106 define therebetween the engine compartment, which is adapted to receive engines of different sizes while defining a space above the left top longitudinal member 104, the space being adapted to receive a component or components of the ATV. In some embodiments, the first distance di may be between about 65 cm and about 45 cm and the second distance d2 may be between about 60 cm and about 40 cm, as described in greater details below.
[00279] Turning now to Figure 17, extending downwardly from cross-member 118a is a left front tube 1 17. Left front tube 1 17 has a top end 121 connected to cross-member 118a, at the junction of upwardly extending left tube 108, and a bottom end 123 attached to a front end 125 of left lower tube 100. With reference to Figure 18, on the right side of the main frame 12, a right-front tube 127 extends downwardly from cross-member 1 18a. Right front tube 127 has a top end 129 connected to cross-member 118a, at the junction of upwardly extending right tube 112, and a bottom end 131 attached to a front end 133 of right lower tube 102.
[00280] As best shown in Figure 22, to connect the front ends 125,133 of the left and right lower tubes 100, 102, at their junction with left and right front tubes 117, 127 is a cross-member bracket 135. In the illustrated embodiment, bracket 135 has a lower plate member 137, and a front flange 139 extending upwardly at the front of lower plate member 137, perpendicularly thereto. As it will become apparent below, front flange 139 of bracket 135 is provided with holes (not shown) for mounting a portion of the front suspension 18 to the main frame 12.
[00281] As it is best shown in Figures 17, 19 and 20, upwardly extending left tube 108, left front tube 117 and the portion of left lower tube 100 (see Figures 17 and 19), as well as upwardly extending right tube 112, right front tube 127 and the portion of right lower tube 102 (see Figure 20), collaborate to triangulate the front end of the main frame 12 to provide additional rigidity to resist the impacts received by the front wheels 16a, 16b and transmitted to the main frame 12 by the front suspension 18 during the operation of ATV 10.
[00282] Referring to Figure 11 , extending sidewardly from the left lower and upper tubes 100, 104 is a left footrest subframe 130 for supporting footrest 32a. Likewise, extending sidewardly from the right lower and upper tubes 102, 106 is a right footrest subframe 132 for supporting footrest 32b. When seen from the left side (see Figure 11), left footrest subframe 130 has a generally U-shape and comprises a front tube 134, a bottom tube 136 and a rear tube 138. The front tube 134 has a top end 140 attached to left, front upwardly extending tube 108, at the junction of left upper tube 104 and upper cross-member 1 18a, and a bottom end 142. Moving from the top end 140 to the bottom end 142, the front tube 134 is curved and extends generally downwardly and rearwardly. At the bottom end 142 thereof, front tube 134 is attached to a front end 144 of the bottom tube 136, while a rear end 146 of the bottom tube 136 is attached to the rear tube 138. More specifically, the rear tube 138 comprises a lower end 150 attached to the rear end 146 of the bottom tube 136, and a generally Y-shaped top end 152 having a main portion 154 attached to a lower left tube 156 of a rear fender portion 158, and a secondary portion 160 attached to an upper left tube 162 of the rear fender portion 158.
[00283] When seen from the right side (see Figure 12), the right footrest subframe 132 has a generally U-shape and comprises a front tube 164, a bottom tube 166 and a rear tube 168. The front tube 164 has a top end 170 attached to right, front upwardly extending tube 110, at the junction of right upper tube 106 and upper cross-member 118a, and a bottom end 172. Moving from the top end 170 to the bottom end 172, the front tube 164 is curved and extends generally downwardly and rearwardly. At the bottom end 172 thereof, the front tube 164 is attached to a front end 174 of the bottom tube 166, while a rear end 167 of the bottom tube 166 is attached to the rear tube 168. More specifically, the rear tube 168 comprises a lower end 171 attached to the rear end 167 of the bottom tube 166, and a generally Y-shaped top end 173 having a main portion 175 attached to a lower right tube 176 of the rear fender portion 158, and a secondary portion 180 attached to an upper right tube 182 of the rear fender portion 158. For the purpose of the describing this and other embodiments, the left and right upper tubes 162, 182 will sometimes be referred to as “longitudinal members” 162, 182 being understood that the terms “upper tubes” are used interchangeably with “longitudinal members” to designate the same corresponding structures identified with the same reference numerals. [00284] Turning to Figures 13 and 14, it can be seen that left and right footrest subframes 130, 132 each defines a generally U-shape when seen from the top (Figure 13) or from the bottom (Figure 14). To maintain left and right footrest subframes 130, 132 into their respective positions, and to provide rigidity thereto, a pair of cross-members 184a, 184b extend between left lower tube 100 and bottom tube 136 of left footrest subframe 130. Likewise, a pair of cross-members 186a, 186b extend between right lower tube 102 and bottom tube 166 of right footrest sub-frame 132.
[00285] As it will become apparent below, left and right subframes 130, 132 provide a structure or frame onto which can be mounted left and right footrests 32a, 32b. Furthermore, as it will be appreciated, left and right footrest subframes 130, 132 contribute to the overall rigidity of the main frame 12.
[00286] Returning now to Figures 1 1 and 12, the rear fender portion 158 comprises left and right lower tubes 156, 176, as well as, left and right upper tubes 162, 182. Left lower tube 156 comprises a front end 190 attached to the left upwardly extending tube 110 (see Figure 11), as well as a rear end 192. Likewise, right lower tube 176 comprises a front end 194 attached to the right upwardly extending tube 114, and a rear end 196 (see Figure 12). As seen from the top (see Figure 13), the left and right lower tubes 156, 176 converge toward one another, from the front ends 190, 194 to the rear ends 192, 196 thereof, while being curved and extending generally upwardly when seen from the side (e.g. Figures 11 and 12) to accommodate the rear drive train 200, as it will become apparent below. With reference to Figure 14, connecting the rear ends 192, 196 of left and right lower tubes 156, 176 of the rear fender portion 158 is a lower, rear cross-member 202. As best shown in Figure 16, lower, rear cross-member 202 partially projects sidewardly from the right lower tube member 176. Returning to Figure 14, the left and right lower tubes 156, 176 are also connected to one another by way of cross-member 204a and 204b, which extend respectively between left and right, upwardly extending tubes 110, 1 14, at the junction of front ends 190, 194, and in an intermediate location between the front ends 190, 194 and the rear ends 192, 196 of left and right lower tubes 156, 176 (best shown in Figure 14).
[00287] Turning now to Figure 13, left upper tube 162 of the rear fender portion 158 comprises a front end 206 and a rear end 208, the front end 206 being attached to crossmember 118c. Likewise, right upper tube 182 of the rear fender portion 158 comprises a front end 210 and a rear end 212, the front end 210 also being attached to cross-member 118c. As seen from the top (see Figure 13), the left and right upper tubes 162, 182 of the rear fender portion 158 diverge away from one another, from their respective front ends 206, 210, toward their rear ends 208, 212. Connecting the rear ends 208, 212 of the left and right upper tubes 162, 182 is an upper rear cross-member 214. The left and right upper tubes 162, 182 are also connected to one another by way of cross-members 216a, 216b, which extends in an intermediate location between the front ends 206, 210 and the rear ends 208, 212 of the left and right upper tubes 162, 182. Extending between the lower and upper cross-members 202 and 214 are two angularly extending tubes 218, 220 (also shown in Figures 14 and 16).
[00288] Returning to Figures 10 and 12, the rear fender portion 158 of the main frame 12 also comprises a right gas tank protecting subframe 222 for protecting a gas tank 201 (not shown in Figure 12) from impacts during the operation of the ATV 10, as it will become apparent below. In the illustrated embodiment, this gas tank protecting subframe 222 comprises a first tube member 224 having a front end 226 attached to the right upper tube 182 of the rear fender portion 158. It also comprises second, third and fourth tube members 228, 230, 231 respectively, for sequentially connecting the first tube member 224 to the right lower tube 176 of the rear fender section 158, at the junction of lower cross-member 202.
[00289] With reference to Figures 17 to 22, the front bumper assembly 13 will now be described in accordance with one embodiment. As it will become apparent below, and as shown in Figures 19 and 20, in this embodiment, the front bumper assembly 13 is configured to be assembled to the main frame 12 using threaded fasteners 232a, 232b and 234a, 234b, which are also used to mount portions of the front suspension 18 between the front bumper assembly 13 and the main frame 12, as it will become apparent below. In the illustrated embodiment (see Figures 17 and 18), front bumper assembly 13 comprises left and right curved tubes 236, 238, each tube having a top end 240, 242 and a lower end 244, 246. At the top ends 240, 242 thereof, the left and right front curved tubes 236, 238 are attached to one another by way of a top cross-member 248. Connecting the lower ends 244, 246 of the left and right curved tube 236, 238 is a mounting plate 250. Mounting plate 250 comprises a pair of holes 252a, 252b (Only hole 252b being shown in Figures 17 and 18) for receiving therethrough a corresponding pair of fasteners 232a, 232b for mounting the lower end of the front bumper assembly 13 to the left and right lower tubes 100, 102 of the main frame 12, as it will be described in greater detail below. Still referring to Figures 17 and 18, the front bumper assembly 13 further comprises an intermediate cross-member 254, extending between the left and right curved tubes 236, 238, in an intermediate location between the top ends 240, 242 and the lower ends 244, 246 thereof, as well as a protective plate 256 extending between the mounting plate 250 and the intermediate cross-member 254.
[00290] Extending proximate to the top ends 240, 242 of left and right curved tubes 236, 238, slightly below the top cross-member 248, are left and right rack support tubes 258, 260. As best shown Figures 19 and 20, respectively, left and right rack support tubes 258, 260 extend generally perpendicular to the top end 240, 242 of the left and right curved tubes 236, 238 toward the rear end of the ATV 10. As such, and referring to Figure 19 the left rack support tube 258 comprises a front end 262 connecting the left curved tube 236, and a rear end 264. Likewise, and referring now to Figure 20 the right rack support tube 260 comprises a front end 266 connecting the right front tube 238, and a rear end 268. At the rear ends 264, 268 thereof, each of the left and right rack support tube 258, 260 is provided with a generally U-Shaped bracket 270, 272, from which extends a crossmember 274. In the illustrated embodiment, and now referring to Figure 17, cross-member 274 comprises a pair of spaced apart downwardly extending tubes 276, 278 secured to the U-shaped brackets 270, 272, and a cross-tube 280 extending therebetween. At the left and right ends of the cross-tube 280 are provided left and right securing brackets 286, 288 (shown in Figure 21), the securing brackets 286, 288 each comprising a hole (not shown) for receiving therethrough a threaded fastener 234a, 234b (shown in Figures 19 and 20) for securing the top end of the bumper assembly 13 to the cross-tube 118a of the main frame 12.
[00291] Turning now to Figures 23 to 30, a second embodiment of a main frame 10012 for use with ATV 10 will now be described. In the embodiment shown in Figures 23 to 30, the main frame 10012 includes a pair of longitudinally extending, left and right lower tubes 10100,10102 defining the lower portion of the main frame, as well as a left, generally Y- shaped upper tube 10104 and a right upper tube 10106. Again, for the purpose of the describing this and other embodiments, the longitudinally extending left and right lower tubes 10100, 10102 and the longitudinally extending left and right upper tubes 10104, 10106 will sometimes be referred to as “bottom longitudinal members” 10100, 10102 or “top longitudinal members” 10104, 10106, being understood that the terms “lower tubes” and “upper tubes” are used interchangeably with “bottom longitudinal members” and “top longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
[00292] As best shown in Figure 24, connecting the left lower tube 10100 and the left upper tube 10104, are front and rear, left upwardly extending tubes 10108, 10110. Likewise, and as best shown in Figure 25, connecting the right lower tube 10102 and the right upper tube 10106 are front and rear right upwardly extending tubes 10112, 10114. Extending between the lowertubes 10100 and 10102 is a plurality of lower cross-members 10116a-10116d (best shown in Figure 27), while upper tubes 10104, 10106 are connected by upper cross-members 10118a-10118d (best shown in Figure 26). While crossmembers 118a-118c of frame 12 are all tubular members extending generally perpendicular to the longitudinal axis of the ATV 10, cross-members 101 18a-101 18d of frame 10012 have a slightly different configuration. More specifically, cross-members 10118a and 10118d are tubular members extending along a transverse axis (i.e., generally perpendicular to the longitudinal axis of the ATV) while cross-member 101 18b extends with an angle relative to the transverse axis. Unlike cross-members 101 18a, 10118b and 10118d which are tubular, cross-member 10118c is made of a stamped sheet of metal. As is will be appreciated, the configuration of cross-members 10118a-10118d can vary without departing from the scope of this embodiment, where some of all of them could all be made of tubular members or stamped sheet of metals, and could adopt different shapes or different angles relative to the longitudinal or transverse axis of the ATV 10. Extending between cross-members 10118a and 10118b is a longitudinal tubular member 10115, configured for attaching the steering column thereto, as it will become apparent below.
[00293] Returning to Figure 23, the front upwardly extending tubes 10108 and 10112 are connected to one another via cross-members 10119a, 10119b. Together, lower tubes 10100, 10102, upper tubes 10104, 10106, front and rear upwardly extending tubes 10108, 10110,10112, 101 14 and cross-members 10116a-101 16d, 10118a-10118d and 101 19a- 10119b define an engine compartment 10120 (see Figures 23 to 25) for receiving the engine (e.g., engine 14 of the ATV 10), as well as a portion of the front and/or rear transmissions (e.g., transmission 20, 26), as it will be described in greater detail below.
[00294] Turning now to Figure 30, extending downwardly from cross-member 10118a is a left front tube 101 17. Left front tube 10117 has a top end 10121 connected to crossmember 101 18a, at the junction of upwardly extending left tube 10108, and a bottom end 10123 attached to a front end 10125 of left lower tube 10100. With reference to Figure 31 , on the right side of the main frame 10012, a right-front tube 10127 extends downwardly from cross-member 10118a. Right front tube 10127 has a top end 10129 connected to cross-member 10118a, at the junction of upwardly extending right tube 10112, and a bottom end 10131 attached to a front end 10133 of right lower tube 10102. [00295] As best shown in Figures 23 to 25, the right top longitudinal member 10106 is at a first distance di from the right bottom longitudinal member 10102 and the left top longitudinal member 10104 is at a second distance d2 from the left bottom longitudinal member 10100. It is understood that the first and second distances di and d2 are measured at corresponding left and right positions along the longitudinal axis. In the illustrated embodiment, the first distance di is greater than the second distance d2 and the left and right bottom longitudinal members 10100, 10102 and the left and right top longitudinal members 10104, 10106 define therebetween the engine compartment, which is adapted to receive engines of different sizes while defining a space above the left top longitudinal member 10104, the space being adapted to receive a component or components of the ATV. In some embodiments, the first distance di may be between about 65 cm and about 45 cm and the second distance d2 may be between about 60 cm and about 40 cm, as it will be best described below.
[00296] As best shown in Figure 31 , to connect the front ends 10125,10133 of the left and right lower tubes 10100, 10102, at their junction with left and right front tubes 10117, 10127 is a cross-member bracket 10135, similar to bracket 135 of frame 12.
[00297] As it is best shown in Figures 31 , 32 and 33, upwardly extending left tube 10108, left front tube 10117 and the portion of left lower tube 10100 (see Figures 31 and 32), as well as upwardly extending right tube 10112, right front tube 10127 and the portion of right lowertube 10102 (see Figure 33), collaborate to triangulate the front end of the main frame 10012 to provide additional rigidity to resist the impacts received by the front wheels (e.g., wheels 16a, 16b) and transmitted to the main frame 10012 by the front suspension (e.g., front suspension 18) during the operation of the ATV 10.
[00298] Referring to Figure 24, extending sidewardly from the left lower and upper tubes 10100, 10104 is a left footrest subframe 10130 for supporting footrest (e.g., footrest 32a). Likewise, and as best shown in Figure 25, is a right footrest subframe 10132 for supporting footrest (e.g., footrest 32b), which extends sidewardly from the right lower and upper tubes 10102, 10106. Left and right footrest subframes 10130 and 10132 being similar to subframes 130 and 132 of frame 12, the description of subframes 130 and 132 is also applicable to subframes 10130 and 10132 respectively, with proper adaptations. Like left and left and right subframes 130, 132 of frame 12, left and right subframes 10130, 10132 provide a structure or frame onto which can be mounted left and right footrests (e.g., left and right footrests 32a, 32b). Furthermore, as it will be appreciated, left and right footrest subframes 10130, 10132 contribute to the overall rigidity of the main frame 10012. [00299] Returning now to Figures 24 and 25, the rear fender portion 10158 comprises left and right lower tubes 10156, 10176, as well as, left and right upper tubes 10162, 10182. For the purpose of the describing this and other embodiments, the left and right upper tubes 10162, 10182 will sometimes be referred to as “longitudinal members” 10162, 10182 being understood that the terms “upper tubes” are used interchangeably with “longitudinal members” to designate the same corresponding structures identified with the same reference numerals. Left lower tube 10156 comprises a front end 10190 attached to the left upwardly extending tube 10110 (see Figure 24), as well as a rear end 10192. Likewise, right lower tube 10176 comprises a front end 10194 attached to the right upwardly extending tube 101 14, and a rear end 10196 (see Figure 25). As seen from the top (see Figure 26), the left and right lower tubes 10156, 10176 are slightly curved toward the right and converge toward one another, from the front ends 10190, 10194 to the rear ends 10192, 10196 thereof, while being curved and extending generally upwardly when seen from the side (e.g. Figures 24 and 25) to accommodate the rear drive train (e.g., drive trains 200 or 10200), as it will become apparent below. Referring to Figure 27, the left and right lower tubes 10156, 10176 are also connected to one another by way of crossmembers 10204a and 10204b, which extend respectively between left and right, upwardly extending tubes 101 10, 101 14, at the junction of front ends 10190, 10194, and in an intermediate location between the front ends 10190, 10194 and the rear ends 10192, 10196 of left and right lower tubes 10156, 10176 (best shown in Figure 27).
[00300] Turning now to Figure 26, left upper tube 10162 of the rear fender portion 10158 comprises a front end 10206 and a rear end 10208, the front end 10206 being attached to the left upwardly extending tube 101 10. Likewise, right uppertube 10182 ofthe rearfender portion 10158 comprises a front end 10210 and a rear end 10212, the front end 10210 being attached right upwardly extending tube 101 14. As seen from the top (see Figure 26), the left and right upper tubes 10162, 10182 of the rear fender portion 10158 diverge away from one another, from their respective front ends 10206, 10210, toward their rear ends 10208, 10212. Connecting the rear ends 10208, 10212 of the left and right upper tubes 10162, 10182 is an upper rear cross-member 10214. The left and right upper tubes 10162, 10182 are also connected to one another by way of a cross-member 10216, which extends in an intermediate location between the front ends 10206, 10210 and the rear ends 10208, 10212 of the left and right upper tubes 10162, 10182.
[00301] Extending between the left and right upper tubes 10162,10182, and the left and right lowertubes 10156, 10176, respectively, are left and right angulartubes 10151 , 10153 (Figure 24, 25 and 29). Left angular tube 10151 comprises a top portion 10154 and a bottom portion 10134. Likewise, right angular tube 10153 comprises a top portion 10137 and a bottom portion 10138. Extending proximal to the junction of the top and bottom portions 10154, 10137 and 10134, 10138, between the left and right angular tubes 10151 , 10153, is a cross-member 10209. Extending at a bottom end of the bottom portions 10134, 10138 of the left and right angular tubes 10151 , 10153 is a lower cross-member 10202. As best shown in Figures 24 and 25, the bottom portions 10134, 10138 and the lower cross-member 10202 extend below the rear ends of the left and right lower tubes 10156, 10176. Secured to the lower cross-member 10202 and extending toward the front of the fender portion 10158, is a sleeve 10228 for receiving a towing attachment. The sleeve 10228 comprises a rear end 10229 secured to the lower cross-member 10202, and a front 10231 end connected to the left and right lower tubes 10156 and 10176 by way of left and right tubes and bracket assemblies 10232, 10233.
[00302] Returning to Figure 25, the rear fender portion 10158 of the main frame 10012 also comprises a gas tank protecting subframe 10222 for protecting a gas tank 10201 (not shown in Figure 25) from impacts during the operation of the ATV 10, as it will become apparent below. In the illustrated embodiment, this gas tank protecting subframe 10222 comprises a first tube member 10224 attached to the right upper tube 10182 of the rear fender portion 10158. It also comprises second tube members 10225, for connecting the first tube member 10224 to the right angular tube 10153, proximal to the junction between the top and bottom portions 10137, 10138 thereof.
[00303] Mounted to the rear fender portion 10158 is a rear rack 10159. The rear rack 10159 comprises a peripheral tube 1200 defining a periphery and having a front end 1202, a back end 1204 and left and right side ends 1206, 1208 (see Figure 26), which together define a space 1210 for receiving therein a storage compartment 1212 (see Figures 1 to 4). Extending on the left and right side ends 1206, 1208, and connecting the front and back ends 1202, 1204 of the peripheral tube 1200, are left and right reinforcing tubes 1214, 1216, as well as left and right reinforcing plates 1218, 1220. At the front end 1202 thereof, the peripheral tube 1200 is bent downwardly such that when the rear rack 10159 is properly positioned on the rear fender portion 10158, the peripheral tube 1200 is proximal to the left and right upper tubes 10162 and 10182, where brackets 1222 and 1224 are provided to secure the peripheral tube 1200 to the left and right upper tubes 10162 and 10182 (see Figures 23 to 25). At the rear end 1204 thereof, the peripheral tube 1200 is provided with left and right, downwardly extending tubes 1226, 1228, for connecting the peripheral tube 1200 to the upper rear cross-member 10214. [00304] With reference to Figures 31 to 34, the front bumper assembly 10013 will now be described, in accordance with one embodiment. As it will become apparent below, and as shown in Figures 31 to 33, in this embodiment, the front bumper assembly 10013 is configured to be assembled to the main frame 10012 using threaded fasteners 10232a, 10232b and 10234a, 10234b, which are also used to mount portions of the front suspension (e.g., front suspension 18) between the front bumper assembly 10013 and the main frame 10012, as it will become apparent below. In the illustrated embodiment, front bumper assembly 10013 comprises left and right curved tubes 10236, 10238, each tube having a top end 10240, 10242 and a lower end 10244, 10246. Proximal to the top ends 10240, 10242 thereof, the left and right front curved tubes 10236, 10238 are attached to one another by way of a top cross-member 10248 (shown in Figure 31). Connecting the lower ends 10244, 10246 of the left and right curved tube 10236, 10238 is a mounting plate 10250, similar to mounting plate 250 of bumper assembly 13. Still referring to Figure 31 , the front bumper assembly 10013 further comprises an intermediate cross-member 10254, extending between the left and right curved tube 10236, 10238, in an intermediate location between the top end 10240, 10242 and the lower end 10244, 10246 thereof, as well as a protective plate 10256 extending between the mounting plate 10250 and the intermediate cross-member 10254.
[00305] Extending at the top ends 10240, 10242 of left and right curved tubes 10236, 10238, is a top rack portion 1300. The top rack portion 1300 comprises a tube 1302 defining a periphery and having a front end 1304, a back end 1306 and left and right side ends 1308, 1310 which together define a space 1312 for receiving a storage compartment 1313 (shown in Figures 1 to 4). Extending on the left and right side ends 1308, 1310, and connecting the front and back ends 1304, 1306 of the peripheral tube 1302, are left and right reinforcing tubes 1314, 1316, as well as left and right reinforcing plates 1318, 1320. With reference to Figure 34, extending from the left reinforcement tube 1316, toward the right and slightly downwardly, is a left bracket mounting tube 1322, having a first end 1324 connected to the left reinforcement tube 1316, and a second end 1326. Connecting the second end 1326 of the left bracket mounting tube 1322 to the rear end 1306 of the peripheral tube 1302 is a connecting member 1328. Extending from the right reinforcement tube 1318, toward the left and slightly downwardly, is a right bracket mounting tube 1330, having a first end 1332 connected to the right reinforcement tube, and a second end 1334. Connecting the second end 1334 of the right bracket mounting tube 1330 to the rear end of the peripheral tube 1302 is another connecting member 1336. [00306] Provided to the left and right bracket mounting tubes 1322 and 1330 are left and right securing brackets 10286, 10288 (shown in Figures 32 and 33), the securing brackets 10286, 10288 each comprising a hole (not shown) for receiving therethrough a threaded fastener 10234a, 10234b (shown in Figures 31 to 33) for securing the top end of the bumper assembly 10013 to the cross-tube 10118a of the main frame 10012.
[00307] Turning now to Figures 35 to 46, a third embodiment of a main frame 35012 for use with ATV 10 will now be described. In the embodiment shown in Figures 35 to 46, the main frame 35012 includes a pair of longitudinally extending, left and right lower tubes 35100, 35102 defining the lower portion of the main frame, as well as a left upper tube 35104 and a right upper tube 35106. As described in connection with the previous embodiments, for the purpose of the describing this and other embodiments, the longitudinally extending left and right lower tubes 35100, 35102 and the longitudinally extending left and right uppertubes 35104, 35106 will sometimes be referred to as “bottom longitudinal members” 35100, 35102 or “top longitudinal members” 35104, 35106, being understood that the terms “lower tubes” and “upper tubes” are used interchangeably with “longitudinal members” to designate the same corresponding structures identified with the same reference numerals.
[00308] As best shown in Figure 36 , connecting the left lower tube 35100 and the left upper tube 35104, are front and rear, left upwardly extending tubes 35108, 35110. Likewise, and as best shown in Figure 37, connecting the right lower tube 35102 and the right upper tube 35106 are front and rear right upwardly extending tubes 35112, 35114. Extending between the lowertubes 35100 and 35102 is a plurality of lower cross-members 35116a-35116f (best shown in Figure 39). One or more of lower cross-members 35116a- 35116f may extend from the left or right lower tubes 35100 and 35102 at an angle other than a right angle. Two or more cross-members 35116a-35116f may intersect each other and/or extend between each other. In the depicted embodiment on Figure 39, crossmember 35116e extends between the right bottom tube 35102 and bottom cross-member 35116f, and bottom cross-member 351 16d extends between left lower tube 35100 and bottom cross-member 35116e. One or more of bottom cross-members 35116a-351 16f may be a stamped sheet of metal. In one embodiment depicted in Figure 39, bottom crossmember 351 16a is made of a sheet of metal. Upper tubes 35104, 35106 are connected by upper cross-members 35118a and 35118b (best shown in Figure 38). While crossmember 351118a of frame 35012 is a tubular member or tube extending generally perpendicular to the longitudinal axis of the ATV 10, cross-member 35118b of frame 35012 has a slightly different configuration. More specifically, cross-member 35118a is a tubular member extending along a transverse axis (i.e., generally perpendicular to the longitudinal axis of the ATV) while cross-member 351 18b is made of a stamped sheet of metal. As will be appreciated, the configuration of cross-members 35118a-35118b can vary without departing from the scope of this embodiment, where some of all of them could all be made of tubular members or stamped sheets of metal, and could adopt different shapes or different angles relative to the longitudinal or transverse axis of the ATV 10. Extending between cross-member 351 18a and right upper tube 35106 is a tube 35115, configured for attaching the steering column thereto, as it will become apparent below.
[00309] Returning to Figure 35, the front upwardly extending tubes 35108 and 35112 are connected to one another via cross-members 35119a-35119c. Together, lower tubes 35100, 35102, upper tubes 35104, 35106, front and rear upwardly extending tubes 35108, 35110, 35112, 35114 and cross-members 35116a-351 16f, 351 18a-35118b and 35119a- 35119c define an engine compartment 35120 (see Figures 35-37) for receiving the engine (e.g., engine 14 of the ATV 10), as well as a portion of the front and/or rear transmissions (e.g., transmission 20, 26), as it will be described in greater detail below.
[00310] Turning now to Figure 42, extending downwardly from cross-member 35118a is a left front tube 351 17. Left front tube 35117 has a top end 35121 connected to crossmember 35118a, at the junction of front upwardly extending left tube 35108, and a bottom end 35123 attached to a front end 35125 of left lower tube 35100. With reference to Figure 43, on the right side of the main frame 35012, a right-front tube 35127 extends downwardly from cross-member 35118a. Right front tube 35127 has a top end 35129 connected to cross-member 35118a, at the junction of front upwardly extending right tube 35112, and a bottom end 35131 attached to a front end 35133 of right lower tube 35102.
[00311] The right upper tube 35106 extends from a right top proximal end portion through a middle portion to a righttop distal end portion. The left uppertube 35104 extends from a left top proximal end portion through a middle portion to a left top distal end portion. The left footrest subframe 35130 extends outwardly sidewardly from the left end portion of the front top cross-member 351 18a or from the left top distal end portion of the left upper tube and downwardly to a left bottom end portion. The right upper tube 35106 is at a first distance di from the right bottom tube 35102 and the left upper tube 35104 is at a second distance d2 from the left lower tube 35100. It is understood that the first and second distances di and d2 are measured at corresponding left and right positions along the longitudinal axis. The first distance di is greater than the second distance d2 and the left and right lower tubes 35100, 35102 and the left and right upper tubes 35104, 35106 define therebetween the engine housing adapted to receive engines of different sizes while the space adapted to receive a component or components of the all-terrain vehicle is defined above the left upper tube 35104 and therebetween the left footrest subframe 35130 and the right upper tube 35106. The first distance di may be between about 65 cm and about 45 cm and the second distance d2 may be between about 60 cm and about 40 cm.
[00312] As best shown in Figure 43, to connect the front ends 35125, 35133 of the left and right lower tubes 35100, 35102, at their junction with left and right front tubes 35117, 35127 is a cross-member bracket 35135, similar to bracket 135 of frame 12.
[00313] As it is best shown in Figures 43, 44 and 45, front upwardly extending left tube 35108, left front tube 351 17 and the portion of left lower tube 35100 (see Figures 43 and 44), as well as front upwardly extending right tube 35112, right front tube 35127 and the portion of right lower tube 35102 (see Figure 45), collaborate to triangulate the front end of the main frame 35012 to provide additional rigidity to resist the impacts received by the front wheels (e.g., wheels 16a, 16b) and transmitted to the main frame 35012 by the front suspension (e.g., front suspension 18) during the operation of the ATV 10.
[00314] Referring to Figure 36, extending sidewardly from the left lower and upper tubes 35100, 35104 is a left footrest subframe 35130 for supporting a footrest (e.g., footrest 32a). Likewise, and as best shown in Figure 37, is a right footrest subframe 35132 for supporting a footrest (e.g., footrest 32b), which extends sidewardly from the right lower and upper tubes 35102, 35106. Left and right footrest subframes 35130 and 35132 being similar to subframes 130 and 132 of frame 12, the description of subframes 130 and 132 is also applicable to subframes 35130 and 35132 respectively, with proper adaptations. Like left and right subframes 130, 132 of frame 12, left and right subframes 35130, 35132 provide a structure or frame onto which can be mounted left and right footrests (e.g., left and right footrests 32a, 32b). Furthermore, as it will be appreciated, left and right footrest subframes 35130, 35132 contribute to the overall rigidity of the main frame 35012.
[00315] Returning now to Figures 36 and 37, the rear fender portion 35158 comprises left and right lower tubes 35156, 35176, as well as, left and right upper tubes 35162, 35182. For the purpose of the describing this and other embodiments, the left and right upper tubes 35162, 35182 will sometimes be referred to as “longitudinal members” 35162, 35182 being understood that the terms “upper tubes” are used interchangeably with “longitudinal members” to designate the same corresponding structures identified with the same reference numerals. Left lower tube 35156 comprises a front end 35190 attached to the cross-member 35116f (see Figures 36 and 39), as well as a rear end 35192. Likewise, right lower tube 35176 comprises a front end 35194 attached to the cross-member 351 16f, and a rear end 35196 (see Figure 37). As seen from the top (see Figure 38), the left and right lower tubes 35156, 35176 are substantially straight and converge toward one another, from the front ends 35190, 35194 to the rear ends 35192, 35196 thereof, while being substantially parallel to the ground when seen from the side (e.g. Figures 36 and 37) and configured to accommodate the rear drive train (e.g., drive train 200), as it will become apparent below. Referring to Figure 39, the left and right lower tubes 35156, 35176 are also connected to one another by way of at least one cross-member 35204.
[00316] Turning now to Figure 38, left upper tube 35162 of the rear fender portion 35158 comprises a front end 35206 and a rear end 35208, the front end 35206 being attached to the left upwardly extending tube 351 10. Likewise, right uppertube 35182 ofthe rear fender portion 35158 comprises a front end 35235 and a rear end 35212, the front end 35235 being attached to the rear right upwardly extending tube 35114. As seen from the top (see Figure 38), the left and right upper tubes 35162, 35182 of the rear fender portion 35158 diverge away from one another, from their respective front ends 35206, 35235, toward their rear ends 35208, 35212. Connecting the rear ends 35208, 35212 of the left and right upper tubes 35162, 35182 is an upper rear cross-member 35214. The left and right upper tubes 35162, 35182 are also connected to one another by way of cross-members 35216a- 35216c, extending in intermediate locations between the front ends 35206, 35235 and the rear ends 35208, 35212 of the left and right upper tubes 35162, 35182.
[00317] Extending between a midpoint on a cross-member 35216a-35216c between the left and right upper tubes 35162, 35182, and the left and right lower tubes 35156, 35176, respectively, are left and right angular tubes 35151 , 35153 (Figure 36, 37 and 41). Left angular tube 35151 comprises a top portion 35154 and a bottom portion 35134. Likewise, right angular tube 35153 comprises a top portion 35137 and a bottom portion 35138. Extending proximal to the junction ofthe top and bottom portions 35154, 35137 and 35134, 35138, between the left and right angular tubes 35151 , 35153, is a cross-member 35209. Extending at a bottom end ofthe bottom portions 35134, 35138 of the left and right angular tubes 35151 , 35153 is a lower cross-member 35202. Bottom portions 35134, 35138 are substantially parallel, while top portions 35154, 35137 extend from the bottom portions to the midpoint on a cross-member 35216a-35216c, converging and connecting to the crossmember at an apex. A hitch assembly as further described herein may be secured to the bottom portions. [00318] Mounted to the rear fender portion 35158 is a rear rack 35159 similar to rear rack 10159 described above. The same numerals are used to denote similar features, or features performing a similar function in the rear rack 35159 of this embodiment as in rack 10159.
[00319] With reference to Figures 43 to 46, the front bumper assembly 35013 will now be described. As it will become apparent below, and as shown in Figures 43 to 46, front bumper assembly 35013 is configured to be assembled to the main frame 35012 using threaded fasteners 35232a, 35232b and 35234a-35234d, which are also used to mount portions of the front suspension (e.g., front suspension 18) between the front bumper assembly 35013 and the main frame 35012, as it will become apparent below. In the illustrated embodiment, front bumper assembly 35013 comprises left and right curved tubes 35236, 35238, each tube having a top end 35240, 35242 and a lower end 35244, 35246. Proximal to the top ends 35240, 35242 thereof, the left and right front curved tubes 35236, 35238 are attached to one another by way of a top cross-member 35248 (shown in Figure 43). A further cross-member 35249 may be disposed between left and right curved tubes. Connecting the lower ends 35244, 35246 of the left and right curved tube 35236, 35238 is a mounting plate 35250, similar to mounting plate 250 of bumper assembly 13. Still referring to Figure 43, the front bumper assembly 35013 further comprises an intermediate cross-member 35254, extending between the left and right curved tube 35236, 35238, in an intermediate location between the top end 35240, 35242 and the lower end 35244, 35246 thereof, as well as a protective plate 35256 extending between the mounting plate 35250 and the intermediate cross-member 35254.
[00320] Extending at the top ends 35240, 35242 of left and right curved tubes 35236, 35238, is a top rack portion 1300. The top rack portion 1300 comprises a tube 1302 defining a periphery and having a front end 1304, a back end 1306 and left and right side ends 1308, 1335 which together define a space 1312 for receiving a storage compartment 1313 (shown in Figures 1 to 4). Extending on the left and right side ends 1308, 1335, and connecting the front and back ends 1304, 1306 of the peripheral tube 1302, are left and right reinforcing tubes 1314, 1316, as well as left and right reinforcing plates 1318, 1320. With reference to Figures 45 and 46, extending from the left and right curved tubes 35236, 35238 towards the main frame 35012 are left and right mounting tubes 351330 and 351332, having one end connected to the left and right curved tubes, respectively, and each being provided with left and right securing brackets 35286, 35288 or other attachment means on the other end for securing to the main frame 35012. Left and right connecting members 351328, 351336 connect the brackets on the left and right mounting tubes 351330 and 351332 to the peripheral tube 1302.
[00321] The securing brackets 35286, 35288 (shown in Figures 44 and 45) each comprise holes (not shown) for receiving therethrough threaded fasteners 35234a-35234d (shown in Figures 43 to 45) for securing the top end of the bumper assembly 35013 to left and right front tubes 35117, 35127 of the main frame 35012.
[00322] As it will be appreciated, the fact that the front bumper assembly 13, 10013 or 35013 is removably attached to the main frame 12, 10012 or 35012, respectively, can be advantageous in a number of ways. For instance, if the bumper assembly 13, 10013 or 35013 becomes damaged because of an impact of the ATV 10 with an obstacle during its operation, the front bumper assembly 13, 10013 or 35013 can be replaced without the need of replacing the entirety of the main frame 12, 10012 or 35012. Furthermore, different front bumper assembly configurations can be used in conjunction with a same main frame 12, 10012 or 35012. For instance, where a same main frame 12, 10012 or 35012 is used, different front bumper assemblies 13, 10013 or 35013 can be used to meet different front rack configurations, or to mount a hitch, a plow or other types of tools commonly used in connection with ATVs such as ATV 10.
[00323] Mounted on the main frame 12, 10012 or 35012, on top of top longitudinal members or uppertubes 104, 106, 10104, 10106, 35104, 35106 and longitudinal members or tubes 162, 182, 10162, 10182, 35162, 35182 of the rear fender portion 158, 10158 or 35158 is the seat 30 (the seat 30 being shown in Figures 1 to 9). As it will be appreciated, the seat 30 can be mounted to the main frame 12, 10012 or 35012 using brackets or other types of intermediate structures, or it can be mounted directly to the main frame 12, 10012 or 35012. Also mounted to the main frame 12, 10012 or 35012 and bumper assembly 13, 10013 or 35013 are fairings (e.g. fairing 10014) for protecting the operator and the internal components of the ATV 10 (shown in Figures 1 to 4).
[00324] The configuration of the main frames 12, 10012 or 35012 and bumper assemblies 13, 10013 or 35013 may prove advantageous in some instances. For instance, the configuration of the main frames 12, 10012 or 35012 enables positioning the seat 30 such that the operator sits in a more forward and lower seating position without significantly altering the wheelbase, ground clearance and suspension travel of the vehicle. Using a model year 2018 Can-Am™ Outlander 450 as a comparison basis, an ATV 10 equipped with a main frame 12, 10012 or 35012 and having a wheelbase of 51 inches (129.5 cm), a front suspension travel of 9 inches (22.9 cm) a rear suspension travel of 8.8 inches (22.4 cm) and a ground clearance of 10.5 inches (26.7 cm), has a seat 30 having a front end at 27.36 inches (695 mm) behind the axle of the front wheels 16a, 16b and a rear end at 49.45 inches (1256 mm) behind the axle of the front wheels 16a, 16b, and a seating portion having a top surface in showroom configuration (/.e. the foam uncompressed) ranging from 24.84 inches (631 mm) above the lowest portion of the main frame 12, 10012 or 35012 (at the proximal to the front end of seat 30) to 25.55 inches (649 mm) above the lowest portion of the main frame 12, 10012 or 35012 (at the rear end of the seat), and a ground clearance (i.e., the distance between the ground and the lowest portion of the main frame 12) ranging from 8.75 inched to 9.25 inches (222.25 mm to 234.95 mm). By comparison, the comparable model year 2018 Can-Am™ Outlander 450 in this instance has a wheelbase of 51 inches (129.5 cm), a front suspension travel of 9 inches (22.9 cm) a rear suspension travel of 8.8 inches (22.4 cm), a ground clearance of 10.5 inches (26.7 cm) and a seat having a seating portion located about 3 inches higher above ground than seat 30 of ATV 10.
[00325] The general configuration of the main frames 12, 10012 or 35012 and bumper assembly provides other various advantages over prior art ATV frame configurations. For instance, the configuration of the main frames 12, 10012 or 35012 and bumper assemblies 13, 10013 or 35013 enables using a variety of shock absorbers having different lengths, and facilitates the assembly of the ATV 10 on the assembly line.
[00326] Figures 47 to 58 show further features of main frame 35012 for the all-terrain vehicle 10, the frame 35012 extending along a longitudinal axis L1-L1 and comprising a front portion 1610, a middle portion 1620 and a rear portion 1700. The front portion 1610 is configured to receive left and right front shock absorbers (not shown) and the rear portion 1700 is configured to receive left and right rear shock absorbers (not shown).
[00327] As best seen in Figures 47 to 50, the middle portion 1620 comprises a left bottom longitudinal member or lower tube 35100 extending from a left bottom proximal end portion 35101a through a middle portion 35101 b to a left bottom distal end portion 35101c, a right bottom longitudinal member or lower tube 35102 extending from a right bottom proximal end portion 35103a through a middle portion 35103b to a right bottom distal end portion 35103c, a left upper tube 35104 extending from a left top proximal end portion 35105a through a middle portion 35105b to a left top distal end portion 35105c, and a right top longitudinal member or upper tube 35106 extending from a right top proximal end portion 35107a through a middle portion 35107b to a right top distal end portion 35107c. [00328] One of the left and right top longitudinal member or upper tubes 35104, 35106 may be at a first distance di from the first left bottom longitudinal member or lower tube 35100 or the right bottom or lower tube 35102. As shown, the right top longitudinal member or upper tube 35106 is at the first distance di from the right bottom longitudinal member or lower tube 35102.
[00329] Another of the left and right top longitudinal member or upper tubes 35104, 35106 may be at a second distance d2 from the left bottom longitudinal member or lower tube 35100 or the right bottom longitudinal member or lower tube 35102. As shown, the left top longitudinal member or upper tube 35104 is at the second distance d2 from the left bottom longitudinal member or upper tube 35100.
[00330] It is understood that the first and second distances di, d2 are measured at corresponding positions along the longitudinal axis L1-L1 (at corresponding left and right positions along the longitudinal axis L1-L1). For instance, the first distance di between the right top longitudinal member or upper tube 35106 and the right bottom longitudinal member or lowertube 35102 may be measured at a right position RP along the longitudinal axis L1-L1 and the second distance d2 between the left top longitudinal member or upper tube 35104 and the left bottom longitudinal member or lowertube 35100 may be measured at a left position LP along the longitudinal axis L1-L1, the right position RP corresponding to the left position LP. For instance, the left position LP may be at 30 cm from the left bottom proximal end portion 35101 a and the right position RP may be at a corresponding 30 cm from the right bottom proximal end portion 35103a.
[00331] As best seen in Figures 47, 55 and 57, the first distance di is greater than the second distance d2. For instance, the first distances di may be between about 65 cm and about 45 cm and the second distance d2 may be between about 60 cm and about 40 cm.
[00332] The first distances di may be between about 65 cm and about 45 cm and the second distance d2 may be between about 60 cm and about 40 cm. More particularly, the first distance di may be between 62 cm and about 61 cm at the left proximal end portion, between about 59 cm and about 61 cm at the left middle portion, and between about 43 cm and about 45 cm at the left distal end portion and the second distance d2 may be between about 62 cm and about 61 cm at the right proximal end portion, between about 53 cm to about 57 cm at the right middle portion, and between about 43 cm and about 45 cm at the right distal end portion. [00333] It is understood that the first and second distances di, d2 may be determined to provide the left and right bottom or lower tubes 35100, 35102 and left and right top or upper tubes 35104, 35106 that define therebetween the housing HO adapted to receive engines of different sizes while a suitable space S is adapted to receive a component of the all-terrain vehicle 10 is defined above the left top longitudinal member or upper tube 35104 and therebetween the left longitudinal member or tube 35130 and the right top longitudinal member or upper tube 35106.
[00334] Referring to Figure 47, the left and right bottom or lower tubes 35100, 35102 and the left and right top or upper tubes 35104, 35106 define therebetween an engine compartment (or engine housing) HO adapted to receive engines having different sizes, such as engine E1 having a first size and an airbox 11500’ (see Figure 52A) and an engine E2 having a second size with an airbox 11500” (see Figure 52B), the second size being larger than the first size. The airbox 1 1500’, 1 1500” may be adapted to the size of the engines E1 , E2 More specifically, and as best seen in Figures 55 and 56, the engine compartment HO is adapted to receive the first engine E1 having the first size. In the illustrated embodiment, the first engine E1 may comprise one cylinder. The monocylinder engine E1 may comprise the cylinder head extending towards the rear end of the all-terrain vehicle 10 (also seen in Figures 55 to 58). For instance, the engine E1 is a Rotax™ 427cc liquid cooled single cylinder. In this embodiment, the engine E1 is mounted in the engine compartment HO, where the cylinder head extends towards the rear end of the ATV 10 (see Figures 55 to 58).
[00335] As best seen in Figures 57 and 58, the engine compartment HO is also adapted to receive the second engine E2 having the second size.
[00336] In the illustrated embodiment, the second engine E2 may be a two-cylinder engine. The first and second engines E1 , E2 may be two-stroke engines, four-stroke engines, diesel engines or an electric motors. Further, each of the engines E1 or E2 may be an in-line, three-cylinder, four-stroke internal combustion engine or a V-twin engine. It is also contemplated that other types of internal combustion engines could be used, such as a two-stroke internal combustion engine. When an electric motor configuration is chosen (not shown), the first and second engines may comprise two, four or six poles. The electric motor (not shown) may have a power of between about 1 to about 300 HP or between about 0.7 to about 220 kW.
[00337] Moreover, as best shown in Figures 47 and 50, a space S is defined above the other of the left and right top longitudinal member or upper tube 35104, 35106 being at the second distance d2. As shown, the space S is defined above the left top upper tube 35104 that is at the second distance d2. Moreover, as shown the space S is defined between the left top longitudinal member or upper tube 35104 and the right top longitudinal member or upper tube 35106.
[00338] The space S is adapted to receive a component or components of the ATV, where the components may be airboxes 11500’, 11500”. It is understood that other components such as a power steering assembly 920’, steering cables 11600a, 11600b, an air filter 11700, a storage compartment (not shown) or a battery (not shown) may alternatively or concurrently be received in the space S.
[00339] As seen in Figures 47 to 49, 53 and 56 to 58, the middle portion 1620 may comprise a first top cross-member 351 18a extending between the left top proximal end portion 35105a of the left top longitudinal member 35104 and the right top proximal end portion 35107a of the right top longitudinal member 35106. The front top cross-member 35118a comprises left and right end portions 1911 , 1912.
[00340] The middle portion 1620 may also comprise a left longitudinal member 35130 extending outwardly sidewardly from the left end portion 1911 of the front top crossmember 351 18a or from the left top proximal end portion 35105a of the left top longitudinal member 35104 and downwardly to a rear left bottom end 1881 . As best shown in Figures 47, 49, 55 and 57, the space S is defined between the left longitudinal member 35130 and the left top longitudinal member 35104.
[00341] Moreover, the middle portion 1620 may comprise a right longitudinal member 35132 extending outwardly sidewardly from the right proximal end portion 1912 of the front top cross-member 351 18a or from the right top proximal end portion 35107a of the right top longitudinal member 35106 and downwardly to a rear right bottom end 1891. The middle portion 1620 may also comprise a front upwardly extending left tube 35108 extending upwardly from the left bottom longitudinal member 35100 up to the first top cross-member 35118a and a front upwardly extending right tube 35112 extending upwardly from the right bottom longitudinal member 35102 up to the first top crossmember 35118a.
[00342] As best seen in Figures 47, 53 to 55 and 57, the middle portion 1620 of the frame 35012 may comprise a first lower cross-member or a cross-member bracket 35135 connecting the left bottom longitudinal member 35100 and the right bottom longitudinal member 35102 at the left and right bottom proximal ends 35101 a, 35103a and a second lower cross-member 35119a comprising left 1931 and right 1932 end portions, and extending between the left bottom longitudinal member 35100 and the right bottom longitudinal member 35102 at the middle portion 35101 b, 35103b of first left and right bottom longitudinal members 35100, 35102. The left end portion 1931 of the second lower cross-member 35119a connects the front upwardly extending left tube 35108 extending upwardly and the left bottom longitudinal member 35100 and the right end portion 1932 of the second lower cross-member 35119a connects the front upwardly extending right tube 35112 extending upwardly and the right bottom longitudinal member 35102.
[00343] The middle portion 1620 may also comprise a second top cross-member 35118b connecting the left and right top longitudinal members 35104, 35106 at respective left and right middle portions 35105b, 35107b of the left and right top longitudinal member or upper tubes 35104, 35106. The space S may be defined above the second top crossmember 35118b;
[00344] As best seen in Figures 47 and 53 to 56, the middle portion 1620 may further comprise a rear left upwardly extending tube 35110 extending upwardly from the left bottom distal end portion 35101 c of the left bottom longitudinal member or lower tube 35100 to the left top distal end portion 35105c of the left top longitudinal member 35104 and a rear right upwardly extending tube 35114 extending upwardly from the right bottom distal end portion 35103c of the right bottom longitudinal member 35102 to the right distal end portion 35107c of the right top longitudinal member 35106.
[00345] As best seen in Figures 53, 54 and 56, the middle portion 1620 of the frame comprises a rear left engine mounting bracket 1810a, 1810a’, a front left engine mounting bracket 1820, 1820’, a rear right engine mounting bracket 1810b, 1810b’ and a front right engine mounting bracket 1822, 1822’. The rear and front left engine mounting brackets 1810a, 1810a’; 1820, 1820’ and the rear and front right engine mounting brackets 1810b, 1810b’; 1822, 1822’ comprise rear and front left connectors (not shown) and rear and front right connectors (not shown) for mounting one of the first and second engines E1 , E2 to the middle portion 1620 in the engine compartment HO.
[00346] The front left engine mounting brackets 1820, 1820’ are removably mounted to the middle portion 35101 b of the left bottom longitudinal member 35100 and/or a bottom end of the front upwardly extending left tube 35108. The front right engine mounting brackets 1822, 1822’ are removably mounted to the middle portion 35103b of the right bottom longitudinal member 35102 and/or a bottom end of the front upwardly extending right tube 351 12. The rear left engine mounting brackets 1810a, 1810a’ are removably mounted adjacent the left bottom longitudinal member 35100 and the rear right engine mounting brackets 1810b, 1810b’ are removably mounted adjacent the right bottom longitudinal member 35102.
[00347] It is understood that each of the first and second engine E1 , E2 comprises a first left and right bottom connectors and a rear bottom connector for allowing respective mounting of the first engine E1 or the second engine E2.
[00348] It is understood that the first left bottom engine mounting bracket 1820, the first right bottom engine mounting bracket 1822, and the rear bottom engine mounting bracket 1810 may be adapted to the size of the engine and the type of left and right bottom connectors, and the rear bottom connector of the engine. As best seen in Figure 54, bottom engine mounting bracket 1820’, the first right bottom engine mounting bracket 1822’, and the rear bottom engine mounting bracket 1810’, or the rear bottom engine mounted brackets 1810a’, 181 Ob’ allow for mounting the second engine E2 being of larger size than the first engine E1 .
Front
[00349] Turning now to Figures 59 to 62, the front suspension 18 will now be described. In the illustrated embodiment, front suspension 18 is a double A-arm suspension (also known as a “double-wishbone suspension”) comprising left and right front suspension subassemblies 292, 294. The left and right front suspension subassemblies 292, 294 being mirror images of one another, only left front suspension subassembly 292 will be described. It will be understood that a similar description also applies to right front suspension subassembly 294, with proper adaptations.
[00350] Left front suspension subassembly 292 comprises a lower A-arm 296, and upper A-arm 298, a knuckle 300, as well as a shock absorber 301 including a dampener 302 and a coil spring 304. The lower A-arm 296 comprises a first end 306 with two mounting points 308a, 308b for mounting the lower A-arm 296 to the main frame 12, and a second end 310 operatively connected to the knuckle 300. Likewise, the upper A-arm 298 comprises a first end 312 with two mounting points 314a, 314b for mounting the upper A-arm 298 to the main frame 12, and a second end 316 operatively connected to the knuckle 300. The knuckle 300 extends between the two second ends 310, 316 of the lower and upper A-arms 296, 298, respectively and allows for securing the left wheel 16a to the front suspension 18 and permits vertical travel movement of the front suspension 18. In the illustrated embodiment, the dampener 302 comprises a lower end 320 attached to the upper A-arm 298, and an upper end 322 for securing the dampener 302 to the main frame 12 of the ATV 10. Concentrically mounted on the dampener 302 is the coil spring 304. Together, the dampener 302 and coil spring 304 mounted to the upper A-arm 298 and to the main frame 12 contribute to control vertical travel movement of the front suspension
18 during the operation of the ATV 10 (and consequently, of the front wheels 16a, 16b attached thereto, the wheels 16a, 16b being shown in Figures 1 to 9).
[00351] As it will be appreciated, the configuration of the left and right front suspension subassemblies 292, 294 can be adjusted so as to control or define the various parameters of the front suspension 18, such as, for instance, the travel, the camber angle, the caster angle, the toe pattern, the roll center height, the scrub radius, bump steer and the like. Furthermore, and as it will be appreciated, bushings and/or bearings are provided at the first and second ends 306, 312, 310 and 316 of the lower and upper A-arms 296, 298, as well as at the lower and upper ends 320, 322 of the dampener 302, to allow proper movement of the front suspension 18 during the operation of the ATV 10.
[00352] Having described the main frame 12, the front bumper assembly 13 and the front suspension 18, the assembly of these three components will now be described. It will be appreciated that, prior to assembling these three components together, other components of the ATV can be pre-assembled to one of these components. Furthermore, the front bumper assembly 13 and/or the front suspension 18 can be assembled together prior to being assembled with the main frame 12, and that the assembly of the main frame 12, the front bumper assembly 13 and/or the front suspension 18 together need not precede other assembly steps required for the assembly of the ATV.
[00353] In accordance with one embodiment, the main frame 12 is first provided. A first set of threaded fasteners 234a, 234b (in this case, a pair of bolts, as shown in Figures 18,
19 and 20) are placed in holes (not shown) defined in the cross-member 118a of the main frame 12. A second set of threaded fasteners 326a, 326b (in this case, also a pair of bolts, shown in Figures 18 and 21) are positioned in holes (not shown) of cross-member 1 19b. A third set of threaded fasteners 324a, 324b (in this case, a pair of bolts, shown in Figures 18 and 22) are positioned in holes (not shown) of cross-member 116b of the main frame. As shown in Figure 17, a fourth set of threaded fasteners 328a, 328b are positioned in cross-member 147 extending between left and right front tubes 117, 127 (fasteners 328a and 328 also being shown in Figures 19 and 20, respectively). Lastly, a fifth set of fasteners 232a, 232b are positioned in holes 141 a, 141 b of cross-member bracket 135 of the main frame 12. With the fasteners in position in their respective holes, the front suspension 18 is now mounted to the main frame 12. More specifically, the rear portion of the second end 316 of the upper A-arm 298 is attached to cross-member 119b, while the front portion of the second end 316 ofthe upper A-arm 298 is secured to the cross-member 147 extending between left and right front tubes 117, 127. In a like manner, the rear portion of the second end 310 of the lower A-arm 296 is attached to the cross-member 1 18a of the main frame 12, while the front portion of the second end 310 is attached to the crossmember bracket 135. The lower end 320 of the dampener 302 onto which is mounted the coil spring 304 is then attached to the upper A-arm 298 while the top end 322 is mounted to the fasteners 234a, 234b extending in the holes of the cross-member 1 18a. At this stage, the various components can be maintained into position on the various threaded fasteners using bolts secured onto the various threaded fasteners 232a, 232b, 234a, 234b, 324a, 324b, 326a, 326b, 328a and 328b. Alternatively, they can be maintained into position using clamps or the like until all bolts are secured. With these components in position, the front bumper assembly 13 can then be assembled to the main frame 12. In the illustrated embodiment, the first set of fasteners 234a, 234b are engaged in the holes (not shown) defined in the brackets 286, 288 of the upper cross-member 274 of the bumper assembly 13 while fasteners 232a, 232b are engaged in holes 252a, 252b of the lower mounting plate 250 of the bumper assembly 13 (see Figure 17). Using bolts, the front bumper assembly 13 is then securely attached to the main frame 12, using appropriate torqueing tools. As it will be appreciated from Figure 11 , in the illustrated embodiment, the top end 322 ofthe dampener 302 is thus sandwiched between the crossmember 274 of the bumper assembly 13 and the cross-member 118a of the main frame 12. Likewise, the front portions of the lower A-arm 296 are sandwiched between the lower mounting plate 250 of the bumper assembly 13 and the cross-member bracket 135 of the main frame 12.
[00354] As it will be appreciated, suspension 18 would be mounted similarly to frame 10012 and front bumper assembly 10013 using fastener 10234a, 10234b, as well as fasteners 10232a, 10232b. As such, the description of the attachment of front suspension 18 to frame 12 and bumper assembly 13 is also application to the attachment of the suspension 18 to the frame 10012 and front bumper assembly 10013, with proper adaptations.
[00355] Referring now to Figure 63, an exploded view of an A-arm structure of a front suspension 75100 will be described. Suspension 75100 may be integrated to an ATV 10 comprising a main frame as described herein and illustrated in Figures 35-46. The suspension comprises left and right lower A-arms 70102, 75112. Each extremity of the lower A-arms defines a circular cavity 75120a-75120d extending along a longitudinal axis, configured to receive bushings 75121 a-75121d. A front bracket 75130 is configured to extend between the front extremities of A-arms 75102, 75112, comprising holes configured to abut the circular cavities 75120a-75120-d and bushings 75121 a-75121d. Fasteners configured to fasten the front extremities of A-arms 75102-75112, bushings 75121 a, 75121 c and front bracket 75130 may comprise bolts 75122a, 75122b and nuts 75123a, 75123b. The fasteners may be further configured to fasten additional elements to those already described, for instance at least one component of a main frame 12, 10012 or 35012. With reference to Figure 43 and with reference to numerals provided therein, when suspension assembly 75100 is mounted on frame 35012, front bracket 75130 is cross-member bracket 35135 and is further configured to receive threaded fasteners 35232a, 35232b for attaching front bumper assembly 35013 to main frame 35012. Accordingly, the cross-member bracket links front bumper assembly 35013 and suspension assembly 75100 to front tubes 35117 and 35227.
[00356] Suspension assembly 75100 further comprises means to attach the rear extremities of lower A-arms 75102, 75112 to a frame such as main frame 12, 10012 or 35012. The means may comprise fasteners, comprising bolts 75124a-75124b, nuts 75125a-75125b and bracket 75126. The fasteners may be configured to attach rear extremities of the A-arms 75102, 751 12, rear bracket 75126, and bushings 75121 b, 75121d to a member 75127, the member 75127 forming part of a main frame 12, 10012 or 35012. With reference to Figure 35, when suspension assembly 75100 is mounted on frame 35012, the member 75127 is cross-member 351 19a.
Method of Assembling
[00357] In one embodiment, a small tubular frame member in the form of a sleeve is secured into the holes ofthe various elements of the main frame 12 (e.g. holes 141 a, 141 b of cross-member bracket 135), as described in US Patent No. 9,815,145 issued on November 14, 2017, the entirety of which is incorporated herein by reference.
[00358] In one embodiment, the various tubular members of the main frame 12, main frame 10012, main frame 35012, front bumper assembly 13, 10013 or 35013 and/or rear suspension 700 (shown in Figures 110 to 115) are secured or attached to one another using the method described in US Patent No. 9,815,145 issued on November 14, 2017, the entirety of which is incorporated herein by reference. As it will be appreciated, other methods for assembly the main frame 12, main frame 10012, main frame 35012, front bumper assembly 13, 10013 or 35013, the rear suspension assembly 700 and/or other components of the ATV 10 are also possible.
Rear Suspension
[00359] Having described the front suspension 18, a first embodiment of a rear suspension 400 will now be described with reference to Figures 64 to 73. In this embodiment, the rear suspension 400 is somewhat of a hybrid between an independent suspension and a classical swing arm suspension. As it will become apparent below, the rear suspension 400 makes use of the torsional characteristics of a specifically designed main swing arm 402 to allow securing of the rear suspension 400 to the main frame 12 of the ATV 10, as well as strategically positioned shock absorbers 41 1 , 413 comprising air/oil dampeners 412, 414 and coil springs 482, 484 (see Figures 71 to 73).
[00360] In the illustrated embodiment, and referring to Figures 66, 67 and 69 the rear suspension 400 comprises the main swing arm 402 having a front end 404 pivotally and/or articulably attached to the main frame 12, 10012 or 35012 of the ATV 10 via brackets 406, 408 (attached to the left and right lower tubes 100, 102 of the main frame 12) or 10406, 10408 (attached to the left and right lower tubes 10100, 10102 of the main frame 10012) and a rear end 410, as well as a pair of shock absorbers 411 , 413 extending between the rear end 410 of the swing arm 402 and the main frame 12 of the ATV 10, as described in greater detail below.
[00361] Turning now to Figure 70, the main swing arm 402 comprises left and right portions 416, 418 attached to one another via a rear differential 420. The left and right swing arm portions 416, 418 being essentially mirror images from one another, only left swing arm portion 416 will be described. The person skilled in the art will appreciate that the same description also applies to right swing arm portion 418, with proper adaptation. In the illustrated embodiment, left swing arm portion 416 comprises a front portion 421 extending from the front end 404 to an intermediate location 422, and a generally T- shaped rear portion 426 extending from the intermediate location 422 to a rear end 424, at which rear end 424 it is attached or secured to a left sleeve portion 428. In the illustrated embodiment, the rear end 424 is welded to the left sleeve portion 428, which left sleeve portion 428 is adapted to rotatably receive a left half-shaft 430 therein.
[00362] The front portion 421 comprises a generally cylindrical tube 437 (/.e. a tube having a generally circular cross-section) extending from the front end 404 to the intermediate location 422. Provided at the front end 404 of the front portion 421 is a cylindrical cavity or recess 435 extending transverse to the longitudinal axis of the cylindrical tube 437. The recess or cavity 435 is configured for receiving a bushing (not shown), for securing the left portion 416 to the bracket 406 of the lower left tube 100 of main frame 12 (shown in Figure 69). In the illustrated embodiment, the bushing (not shown) allows the left portion 416 to pivot about the pivot axis P-P (see Figure 69), as well as torsion movement LT -LT of left portion 416 of the swing arm relative to its attachment point (/.e. bracket 406) on the main frame 12, without compromising the pivoting movement about axis P-P. Returning to Figure 70, at their junction (/.e. at the intermediate location 422) the front and rear portions 421 , 426 are welded together. While in the illustrated embodiment the left portion 416 of the swing arm 402 is made of two separate components welded together (/.e. the front and rear portions 421 , 426), the person skilled in the art will appreciate that it could be manufactured as a single piece, as it will become apparent below, with reference to Figures 78 to 84. Furthermore, while in the illustrated embodiment the rear portion 426 is welded to the left sleeve 428, the rear portion 426 could be secured to the left sleeve 428 differently, for instance using nuts, bolts, brackets, collars or any other type of suitable fastening means.
[00363] Unlike the front portion 421 , which has a generally circular cross-section, the rear portion 426 has a generally oblong cross-section. In one embodiment, the rear portion 426 is sized, shaped and made of a material allowing a limited torsion of the rear portion 426 about a longitudinal axis LT-LT (see axis LT -LT on Figure 69). Together with bushings at the front end 404, the torsional properties of the rear portion 426 allow the main swing arm 402 to twist along a longitudinal axis, therefore providing further degrees of freedom to the rear suspension 400 than conventional swing arms. In one embodiment, the left swing arm portion 416 is made of Strenx™ 700 structural steel having a 0.0551 inch (1.4 mm) thickness.
[00364] Again referring to Figure 70, the left sleeve 428 comprises a wheel end 432 (/.e. the end shown on the left in Figure 70) and a differential end 434 (/.e. the end shown on the right in Figure 70). At the wheel end 432, the sleeve 428 is provided with a counterbored flange 436 configured for receiving therein a wheel bearing 438, and comprising a plurality of holes for receiving a corresponding plurality of threaded fasteners 440a-440d (in Figure 70, only fasteners 440a and 440b are shown) for maintaining the wheel bearing 438 in the counterbored flange 436 and the left half shaft 430 attached thereto, as it will become apparent below. At the right or differential end 434 thereof, the sleeve 428 is provided with a radially extending flange 442 in which are defined a plurality of holes 443a-443d (in Figure 70, only holes 443a and 443b are shown). As it will become apparent below, the holes 443a-443d defined in flange 442 are sized and positioned for receiving a plurality of fasteners 444a-444d therethrough, for securing the left portion 416 of the swing arm 402, the differential 420 and the right portion 418 of the swing arm 402 together.
[00365] The differential 420 comprises a generally cylindrical casing 450 for housing the gears of the differential (not shown), the casing 450 having a generally circular left wall 452, a generally circular right wall 454 and a curved wall 456 extending between the left and right walls 452, 454, respectively. Defined in the curved wall 456, about the periphery of the differential 420, are a plurality of holes 457a-457d (in Figure 70, only holes 457a and 457b are shown) for receiving the corresponding plurality of threaded fasteners 444a- 444d. As it will become apparent below, the holes 443a-443d defined in the flange 442 of the left portion 416 and the flange 442 of the right portion 418 are in registry with the holes 457a-457d defined in the curved wall 456 of the differential 420 such that the left and right portions 416, 418 of the main swing arm 402 are attachable to the differential 420 by way of threaded fasteners 444a-444d to complete the assembly of the main swing arm 402. As it will be appreciated, in this embodiment, the casing 450 of the differential 420 thus plays a structural role in the main swing arm 402. As such, the casing 450 of the differential is sized and shaped so as to resist the various forces encountered by the rear transmission during the operation of the ATV 10. In one embodiment, the casing of the differential is made of aluminum, but it is contemplated that it could be made of any other suitable material.
[00366] In an alternate embodiment (shown in Figures 64 to 69) the main swing arm 402 further comprises a hitch 460. As best shown in Figures 64, 66 and 67, in this embodiment, the hitch 460 comprises a pair of spaced-apart plate members 462, 464, each plate member 462, 462 having a circular portion (not shown) generally corresponding to the circular walls 452, 454 of the differential casing 450, and a tapering rear portion 466, 468. Defined on the periphery of the circular portion of each of the left and right plate members 462, 464 is a plurality holes (not shown), distributed to align with corresponding holes 443a-443d of the right and left flanges 442 of the left and right portions 416, 418 of the main swing arm 402, respectively, as well as with the holes 457a-457d defined in the curved wall 456 of the differential housing or casing 450. Extending between the tapering portions 466, 468 of the left and right plate members 462, 464 is a cross-plate 470, configured for receiving a tow ball 472 or another type of attaching device for attaching a trailer to the ATV 10. As it will be appreciated, the hitch 460 could alternatively be used to attach a winch or another type of attachment commonly used on ATVs. In the embodiment illustrated in Figures 64 to 69, the hitch 460 becomes part of the main swing arm 402 by attaching the circular portions (not shown) of the left and right plate 462, 464 on each side of the differential casing 450. More specifically, the circular portion (not shown) of the left plate 462 is received between the right flange 442 of the left portion 416 and the left circular wall 452 of the differential casing 450. Likewise, the circular portion (not shown) of the right plate member 464 is received between the right circular wall 454 of the casing 450 and the left flange 442 of the right portion 418 of the main swing arm 402. The holes 443a- 443d of the right flange 442 of the left portion 416, the left circular plate of the plate member 462, the holes 457a-457d of the casing 450, the holes of the right plate member 464 and the holes of the left flange 442 of the right portion 418 being in registry, threaded fastener 444a-444d can be used to secure the various components of the main swing arm 402. Furthermore, while in the above-described embodiment the hitch 460 is manufactured as a part that is distinct from the differential 420, it will be understood that other configurations are possible. For instance, the hitch 460 could be integrally formed with the casing 450 of the differential 420.
[00367] While in the above-described embodiment, the casing 450 of the differential 420 is a discrete component, it will be understood that other configurations are possible. For instance, the differential 420 could form an integral structure with sleeves 428 of the left and right portions 416, 418. Furthermore, while in the illustrated embodiment the rear differential 420 is structural and is used to connect the left and right rear portions 416, 418, the person skilled in the art will appreciate that the rear suspension configuration could be used with any other type of transmissions, including more classical rear axles.
[00368] Extending from the front of the differential 420 is the rear driving shaft 480 (shown in Figures 69 to 71), which is operatively coupled to the engine 14 (shown in Figures 3 to 6) of the ATV 10 via rear transmission (not shown), as known to those skilled in the art.
[00369] With reference to Figures 66, 68 and 69, to mount the main swing arm 402 to the main frame 12 of the ATV, the front end 404 of the left and right portions 416, 418 of the main swing arm 402 are positioned into the brackets 406, 408 secured to the left and right lowertubes 100, 102 of the main frame 12 (see Figures 66 and 67). The left and right rear dampeners 412, 414, onto which are mounted left and right coil springs 482, 484 (shown in Figures 71 to 73), are then positioned to connect the main swing arm 402 to the main frame 12 and to allow a pivotal movement of the main swing arm 402 relative to the main frame 12 along a horizontal axis (/.e. up and down movement), as well as torsional moment of the swing arm 402 about the longitudinal axis of the ATV 10, the pivoting and torsional axes being shown in Figures 68 and 69. With reference to Figure 71 , the left rear dampener 412 comprises a lower end 486 attached to a bracket 488 on the left swing arm portion 416, and an upper end 490 mounted to a bracket 492 found at the junction of rear, left upwardly extending tube 110 of the main frame 12 and upper left tube 162 of the rear fender portion 158 of the main frame 12 (shown in Figure 66). Likewise, the right rear dampener 414 comprises a lower end 494 attached to a bracket 496 of the right swing arm portion 418 (shown in Figure 71), and an upper end 498 mounted to a bracket 500 found at the junction of rear, right upwardly extending tube 114 of the main frame 12 and right upper tube 182 of the rear fender portion 158 of the main frame 12 (shown in Figure 67). In one embodiment, shown in Figures 72 and 73, the left and right shock absorbers 41 1 , 413 in the showroom state define an angle 0i ranging from about 25 degrees to about 35 degrees relative to a vertical plan extending along the longitudinal axis of the ATV and an angle 02 ranging from about 40 degrees to about 50 degrees relative to a vertical plan extending perpendicular to the longitudinal axis of the ATV 10. In one implementation, the left and right shock absorbers 411 , 413 in the showroom state define an angle 01 of 30.591 degrees and an angle 02 of 45.466 degrees.
[00370] As best shown in Figure 69, when the rear suspension is mounted to the main frame 12 of the ATV 10, the left and right portions 416, 418 of the main swing arm 402 are positioned on the exterior sides of the left and right lower tube members 100, 102 of the main frame 12, as well as on the exterior sides of the lower tubes 156, 176 of the fender portion 158 ofthe main frame 12. Furthermore, the tapering profile of the rear portions 426 of the left and right portions 416, 418 ofthe swing arm 402 are parallel to, but spaced apart from, the left and right lower tubes 100, 102 of the main frame 12, and the lower tubes 156, 176 of the fender portion 158 of the main frame 12. As such, the main swing arm 402 is free to pivot or travel upwardly and downwardly relative to the main frame 12, between a showroom state (shown in Figures 66 and 68) and bump state (shown in Figures 74 to 77). Furthermore, the space separating the left and right portions 416, 418 of the main swing arm 402, being wider than the space found between frame members of typical prior art swing arms, contribute to increase the torsional movement of the main swing arm 402 about the longitudinal axis (shown in Figure 68).
[00371] Referring to Figures 78 to 84, a second embodiment of a rear suspension 10400 is shown. In the illustrated embodiment, the rear suspension 10400 is mounted to the frame 10012, but it will be understood that it could also me mounted to frame 12. [00372] Rear suspension comprises ta main swing arm 402 having a front end 404 pivotally and/or articulably attached to the main frame 10012 of the ATV 10 (or frame 12) via brackets 10406, 10408 (attached to the left and right lower tubes 10100, 10102 of the main frame 10012) and a rear end 10410, as well as a pair of shock absorbers 10411 , 10413 extending between the rear end 10410 of the swing arm 10402 and the main frame 10012 of the ATV 10, as described in greater detail below.
[00373] Turning now to Figure 83, the main swing arm 10402 comprises left and right portions 10416, 10418 attached to one another via a rear differential 10420. The left and right swing arm portions 10416, 10418 being essentially mirror images from one another, only left swing arm portion 10416 will be described. The person skilled in the art will appreciate that the same description also applies to right swing arm portion 10418, with proper adaptation. In the illustrated embodiment, left swing arm portion 10416 comprises a front portion 10421 extending from the front end 10404 to an intermediate location 10422, and a generally T-shaped rear portion 10426 extending from the intermediate location 10422 to a rear end 10424, at which rear end 10424 it is attached or secured to a left sleeve portion 10428. In the illustrated embodiment, the rear end 10424 is welded to the left sleeve portion 10428, which left sleeve portion 10428 is adapted to rotatably receive a left half-shaft 10430 therein.
[00374] Unlike front and rear portions 421 and 426 of rear suspension 400, the front portion 10421 and rear portion 10426 of rear suspension 10400 are made of a single piece. The other elements of the rear suspension 10400 being essentially identical to those of rear suspension 400, it will be understood that the description of those elements in connection with rear suspension 400 is also applicable to rear suspension 10400, with proper adaptation. Furthermore, the rear portion 10426 having a generally oblong crosssection, and being sized, shaped and made of a material allowing a limited torsion of the rear portion 10426 about a longitudinal axis LT -LT (see axis LT -LT on Figure 80), as well as the gradually tapering front portion 10421 , provides the rear portion 10426 with torsional properties. Together with bushings at the front end 10404, the torsional properties of the rear portion 10426 allow the main swing arm 10402 to twist along a longitudinal axis, therefore providing further degrees of freedom to the rear suspension 10400 than conventional swing arms. In one embodiment, the left swing arm portion 10416 is made of Strenx™ 700 structural steel having a 0.0551 inch (1 .4 mm) thickness.
Rear Drive Axle [00375] Returning to Figure 70, the rear drive train 200 comprises left and right drive half shafts 430 and 530. The left and right drive half shafts 430, 530 being similar, only left half shaft 430 will be described. It will be appreciated that a similar description also applies to right half shaft 530, with proper adaptations.
[00376] Left half shaft 430 is sized and shaped to be received in left sleeve 428 of the main swing arm 402, the left half shaft 430 having a left end 532 to which is mounted a hub 534 and a splined right end 536 receivable in the differential 420 and collaborating with a corresponding splined bore (not shown) for allowing motion of the left rear wheel 22a. At the left end 532 thereof, the diameter of the half shaft 430 is slightly wider than the inner diameter of the inner race of the bearing 438, such that the bearing 438 can be secured to the left end 532 of the half shaft 430 by frictional engagement, and prevent unwanted movement of the bearing 438 relative to the half shaft 430. In one embodiment, the bearing 438 is mounted to the left end 532 of the half shaft 430 using a hydraulic press, by heat treating the bearing 438 prior to its assembly onto the half shaft 430, or using a combination of both. Once the bearing 438 is secured to the left end 532 of the half shaft 430, the left half shaft 430 is slid into the left sleeve 428, until the splined end 536 engages the corresponding splined bore (not shown) of the differential 420. At this point, the bearing 438 of the left half shaft 430 is received in the counterbored flange 436 extending at the left end 432 of the sleeve 428, the left side 538 of the bearing 438 being close to be in alignment with the counterbored flange 436. At this point, bolts (not shown in Figure 70) are secured onto threaded fasteners 540a-540d, the bolts engaging the outer race of the bearing 438. As the bolts are further screwed on the threaded fastener 540a-540d, they force the bearing 438 into the counterbored flange 436 until the left half shaft 430 is properly positioned into sleeve 428. As it will be appreciated, since only the outer race of the bearing 438 is engaged by the bolts, the inner race of the bearing is free to rotate, thereby allowing rotation of the left rear wheel 22a.
[00377] In one embodiment shown in Figure 71 , the hub 534 provided at the left end 532 of the left half shaft 430 comprises a central portion 542 and a plurality of projections 544a-544d extending radially from the central portion 542. Each of the radial projections 544a-544d comprises a hole 546a-546d for receiving therein a threaded fastener 548a- 548d (shown in Figure 73), the threaded fasteners 548a-548d of the plurality of projections 544a-544d being used to secure the left rear wheel 22a to the hub 534. Still in Figure 71 , the hub 534 comprises four (4) radial projections distributed symmetrically about the central portion 554, such that a space 550a-550d is defined between each pair of adjacent projections e.g. between projections 544a and 544b). Likewise, and as best shown in Figure 73, the rim 552 of the rear wheel 22a is provided with corresponding spaces 554a- 554d between each pair of adjacent spokes 556a-556d. In this embodiment, the spaces between the pair of adjacent projections (e.g. space 550a) and the spaces between the spokes of the wheel (e.g. space 554a) are adapted for providing access to the bolts (not shown) used for securing the left half shaft 430 into position in the left sleeve 428. As such, the configuration of the illustrated embodiment allows removing the left half shaft 430 from the left sleeve 428 without having to remove the left rear wheel 22a form the hub 534, and, conversely to assemble the left half shaft 430 into the left sleeve 428 while the left rear wheel 22a is mounted to the hub 534. This can prove to be advantageous, for instance on the assembly line of the ATV. Furthermore, such a configuration contributes to avoiding the use of joints, which may be more prone to wear and tear.
[00378] Turning now to Figures 83 and 84, the rear drive train 10200 comprises left and right drive half shafts 10430 and 10530, in accordance with an alternate embodiment. The left and right drive half shafts 10430, 10530 being similar, only left half shaft 10430 will be described. It will be appreciated that a similar description also applies to right half shaft 10530, with proper adaptations.
[00379] Left half shaft 10430 is sized and shaped to be received in left sleeve 10428 of the main swing arm 10402, the left half shaft 10430 having a splined left end 10532 comprising a threaded portion 10533 to which can be mounted a hub 10534 and a splined right end 10536 receivable in the differential 10420 and collaborating with a corresponding splined bore (not shown) for allowing motion of the left rear wheel (e.g., rear wheel 22a). At the left end 10532 thereof, the diameter of the half shaft 10430 is slightly smaller that the inner diameter of the inner race of the bearing 10438, such that the bearing 10438 can be mounted about the left end 10532 of the half shaft 10430, as it will become apparent below.
[00380] To mount the half shaft 10430 into the sleeve 10428, the splined right end 10536 is engaged into the sleeve 10428 the left half shaft 10430 is slid into the left sleeve 10428, until the splined end 10536 engages the corresponding splined bore (not shown) of the differential 10420. The bearing 10438 is then mounted to the left end 10532 of the half shaft and slid until it is received into a counterbored flange 10436 of the sleeve 10428. Once the bearing 10438 is mounted to the left end 10532 of the half shaft 10430 and is received in the counterbored flange 10436, a C-clip 10437 is positioned in the counterbored flange 10436 to secure the bearing 10438 in position, thereby preventing the half shaft 10430 to move out from its operating position. At this point, the hub 10534 comprising a splined hole (not shown) is engaged onto the left end 10532 of the half shaft 10530, and a bolt 10535 is secured onto threaded 10533 portion to secure the hub 10534 to the left end 10532 of the half shaft 10430.
[00381] As it will be appreciated, the main swing arms 402 and 10402 could be used with any one of rear drive train 200 or 10200, or with other drive train configurations, without departing from the scope of the invention.
Gas Tank and Muffler Configuration
[00382] In one embodiment, and as best shown in Figures 75 to 77, the gas tank 201 of the ATV 10 is adapted to be mounted to the rear fender portion 158 of the main frame 12. In this embodiment, the gas tank 201 is sized and shaped for receiving a suitable volume of gas (e.g. 5.4 gal. or 20.5 litres), and yet provide the rear suspension 400 with sufficient clearance for the main swing arm 402 to move between the fully extended position and the full-bump position. As best shown on Figures 85 and 91 , the gas tank 201 has a generally bean shape when seen from either the left side or the right side (see Figures 85 and 91), and a generally L-shape when seen from the front or from the back (see Figures 86 and 87). More specifically, and as best shown in Figures 86 and 87 the gas tank 201 has a wider upper portion 600 which is adjacent to the right upper tube 182 of the rear fender portion 158 when the gas tank 201 is assembled to the main frame 12 (see Figure 77), and a lower, narrower portion 602. With reference to Figure 86, in the illustrated embodiment, the gas tank 201 includes a top wall 604 having a generally straight, forward portion 606, and a rear, inclined portion 608. Extending downwardly from the forward portion 606, at the front end of the gas tank 201 , is a front wall 610. At the rear end of the rear inclined portion 608, is a downwardly extending back wall 612. To define the lower, narrower portion 602 of the gas tank 201 , a bottom wall 614 extends between the front wall 610 and the back wall 612, the bottom wall 614 comprising first, second, third and fourth portions 616, 618, 620 and 622, respectively, extending sequentially from the front end to the rear end. Furthermore, and as best shown in Figures 86 and 87 the lower narrower portion 602 includes a pair of left and right side walls 624, 626, respectively.
[00383] Still referring to Figures 86 and 87, extending between the front end and the rear end of the upper, wider portion 600 is a left side wall 628 and a bottom wall 630. On the right side thereof, the bottom wall 630 of the upper, wider portion 600 connects with the vertically extending left side wall 624 of the lower, narrower portion 602 to define somewhat of an L-shaped recess 632. [00384] The gas tank 201 also includes a neck 634 (shown in Figures 85 and 86), a fuel line, a fuel meter/fuel pump, a strainer and other parts typically required for operatively connecting the gas tank 201 to the engine 14.
[00385] Returning to Figures 76 and 77, when the gas tank 201 is mounted to the fender portion 158 of the main frame 12, the lower, narrower portion 602 is vertically aligned with the right arm portion 418 of the main swing arm 402, and the wider, upper portion 600 extends above the differential 420. In this embodiment, the recess 632 defined by the bottom wall 630 of the wider portion 600 and the left wall 624 of the narrower portion 602 is configured for receiving the differential 420, when the rear suspension 400 is in a fullbump position, while first, second, third portions 616, 618 and 620 of the bottom wall 614 of the narrower portion 602 are configured to accommodate the presence of the rear portion 426 and sleeve 428 of the right arm portion 418 of the main swing arm 402. In one embodiment, the gas tank 201 is mounted to the cross-members 216a (cross-member 216a being shown in Figure 13) and 202 of the rear fender portion 158 via a front tab 654 extending frontwardly from front wall 610 of gas tank 201 and a rear tab 656 extending rearwardly from back wall 612, using threaded fasteners 658 and 660, and via side tab 662 extending sidewardly from side wall 626 and attached to tube member 228 using threaded fastener 664 (see Figures 74, 76 and 77).
[00386] Referring to Figures 74 and 77, the exhaust system 650 is configured for allowing full travel of the main swing arm 402 between the showroom position and the fullbump position. In the illustrated embodiment, the exhaust system 650 comprises a muffler 652 mounted to the rear fender portion 158 of the main frame 12, generally under the left upper tube 162 of the fender portion 158. The muffler 652 is sized, shaped and positioned on the rear fender portion 158 such that, together with the configuration of the gas tank 201 , a space or recess is provided for accommodating the differential 420 when the rear suspension 400 is in full bump position. The position of the gas tank 201 and of the muffler 652 contribute to balance the fore/aft weight of the ATV 10, since the configuration of the frame assembly (/.e. main frame 12, front bumper assembly 13 and rear suspension 400) tends to move the rider in a position that is more forward than on conventional ATVs and the displacement of the rider’s weight towards the front end of the ATV is advantageously counterbalanced by moving the gas tank 201 further rearward of the vehicle, as illustrated in this embodiment.
[00387] Returning to Figure 77, it will be appreciated that the cross-member 202 of the rear fender portion 158 acts as a stopper for preventing unwanted impact of a trailer portion (not shown) attached to the trailer hitch 460, when the main swing arm 402 moves from the showroom position to the bump position (the bump position being shown in Figure 77). However, as the lower, narrower portion 602 of the gas tank 201 extends below crossmember 202 of the rear fender portion 158, on the right side thereof, the gas tank 201 is prone to impact with the portion of the trailer (not shown) attached to the trailer hitch 460 as the rear suspension 400 is in a full-bump state and the ATV 10 is making a right turn. As such, the subframe 222 is provided to protect the gas tank 201 in such operating condition. As best shown in Figure 61 , the tubes 224, 228, 230 and 231 of the subframe 222 are configured to substantially match the contour of the bottom wall 614 of the lower portion 602 of the gas tank 201 and to prevent a trailer hitch or attachment from contact with the gas tank 201 during the operation of the ATV 10.
[00388] While in the above embodiment the gas tank 201 is located on the right side of the rear fender portion 158 and the muffler 652 is located on the left side, it will be understood that this configuration could be mirrored and the gas tank 201 be located on the left side and the muffler on the right side of the fender portion 158. Furthermore, it will be appreciated that alternate muffler and/or gas tank configurations are also possible without departing from the scope of the embodiment.
[00389] Referring now to Figures 92 to 96, such alternate muffler and gas tank configurations are shown, for use with the main frame 10012. In this alternate embodiment, the gas tank 10201 of the ATV 10 is adapted to be mounted to the rear fender portion 10158 of the main frame 10012. In this embodiment, the gas tank 201 is sized and shaped for receiving a suitable volume of gas (e.g. 5.4 gal. or 20.5 liters), and yet provide the rear suspension 10400 with sufficient clearance for the main swing arm 402 to move between the fully extended position and the full-bump position. Much like the gas tank 201 , gas tank 10201 has a generally bean shape when seen from either the left side or the right side (see Figures 93 and 96), and a generally L-shape when seen from the front or from the back. More specifically, and as best shown in Figure 93, the gas tank 10201 has a wider upper portion 10600 which is adjacent to the right upper tube 10182 of the rear fender portion 158 when the gas tank 10201 is assembled to the main frame 10012, and a lower, narrower portion 10602. The gas tank 10201 also includes a neck 10634 (shown in Figures 92, 93 and 95), a fuel line, a fuel meter/fuel pump, a strainer and other parts typically required for operatively connecting the gas tank 10201 to the engine 14. [00390] When the gas tank 201 is mounted to the fender portion 10158 of the main frame 10012, the lower, narrower portion 10602 is vertically aligned with the center of the rear fender 10158, and extends downwardly between the left and right lower frame members 10156, 10176. As best shown in Figure 96, a recess 10635 is defined in front of the narrower portion, so as to provide space for the differential 10420, therefore allowing full travel of the main swing arm 10402 between a showroom position and a full-bump position. In one embodiment, the gas tank 10201 is mounted to the cross-members the rear fender portion 10158 via a plurality of tabs 10654 extending, using threaded fasteners 10658. With reference to Figures 23 to 25 and 96, it will be appreciated that left and right angular tubes 10151 , 10153, cross-members 10202, 10209, tube members 10224, 10225, as well as sleeve 10228 of the rear fender portion 10158 acts as a guard or bumper for preventing unwanted impact of the main swing arm 10402 moving from the showroom position to the bump position or with obstacles.
[00391] Referring to Figures 92 to 95, the exhaust system 10650 is also configured for allowing full travel of the main swing arm 10402 between the showroom position and the full-bump position. In the illustrated embodiment, the exhaust system 10650 comprises a muffler 10652 mounted to the rear fender portion 10158 of the main frame 10012, generally under the left upper tube 10162 of the fender portion 10158. The muffler 10652 is sized, shaped and positioned on the rear fender portion 10158 such that, together with the configuration of the gas tank 10201 , a space or recess is provided for accommodating the differential 10420 when the rear suspension 10400 is in full bump position. Much like the position of the gas tank 201 and of the muffler 652, the position of the gas tank 10201 and of the muffler 10652 contribute to balance the fore/aft weight of the ATV 10.
Alternate Rear Suspension Configuration
[00392] In an alternate embodiment, shown in Figures 97 to 112, the ATV 10 is provided with a different rear suspension configuration 700. In this alternate embodiment, the rear suspension 700 is an independent suspension configured to be mounted to the main frame 12. Rear suspension 700 comprises a rear suspension frame 702 to which are attached left and right double A-arm suspensions 704, 706 (only a portion of right double A-arm suspension 706 being shown in Figures 97 and 99).
[00393] With reference to Figures 103 to 105, the rear suspension frame 702 comprises left and right tubular members 710, 712, each of the left and right tubular members 710, 712 having a front end 714, 716 attachable to the brackets 406, 408 of the main frame 12 (the brackets 406, 408 being shown in Figures 97 to 102), and a rear end 718, 720. Still referring to Figures 103 to 105, from the front ends 714, 716 to the rear ends 718, 720 thereof, the left and right tubular members 710, 712 converge slightly toward one another. Extending between the rear ends 718, 720 of the left and right tubular members 710, 712 is a cross-member 722, in which are defined a pair of holes 724a, 724b for mounting portions of the double A-arm suspensions 704, 706, as it will become apparent below. In intermediate locations between the front ends 714, 716 and the rear ends 718, 720 of left and right tubular members 710, 712, cross-members 726 and 728 are provided.
[00394] Mounted to the rear cross-member 722 and to the rear ends 718, 720 of tubular members 710, 712 is rear structure 730 having a generally triangular shape when seen from the side (best shown in Figures 103, 104 and 106). This rear structure 730 comprises left and right rearwardly inclined tubes 732, 734, each having a lower end 736, 738, respectively, attached to the cross-member 722. Rearwardly inclined tubes 732, 734 also have upper ends 740, 742 connected to upper tubes 758, 760, respectively. The rear structure 730 has also frontwardly inclined tubes 744, 746 each having a lower end 748, 750 attached to the rear end 718, 720 of the left and right tubular members 710, 712, respectively. The frontwardly inclined tubes 744, 746 also include upper ends 752, 754, respectively. A cross-tube 756 connects the upper ends 752, 754 of the frontwardly inclined tubes 744, 746, and upper tubes 758, 760, each having a front end 762, 764, and rear ends 766, 768, connect the cross-tube 756 connected to the upper ends 740, 742 of the rearwardly inclined tubes 732, 734. Mounted to the upper ends 740, 742 of the rearwardly inclined tubes 732, 734, and extending between the same, is a bracket 770 having a generally U-shaped cross-section. As best shown in Figures 104, 105 and 108, defined in the bracket 770 are two pairs of holes 772, 774, each pair of holes 772, 774 comprising a first hole 772a, 774a defined in a front flange 776 of the bracket 770 and a second hole 772b, 774b defined in a rear flange 778 of the bracket 770. Cross-member 780 joins member 732 with member 734 between their respective upper and lower ends, 740, 742 and 736, 738. Holes 782a and 782b are defined within cross-member 780 to mount other rear suspension components thereto.
[00395] To mount the rear suspension frame 702 to the main frame 12 of the ATV 10, best shown in Figures 97, 99 and 101 , the front ends 714, 716 of left and right tubular members 710, 712 are engaged in the mounting brackets 406, 408 of the main frame 12, and secured into position using threaded fasteners (not shown). The U-shaped bracket 770 is then positioned adjacent to the rear-cross-member 202 of the rear fender portion 158, the front and rear flanges 776, 778 being positioned respectively at the front and at the rear of cross-member 202. Threaded fasteners 784a, 784b (only threaded fasteners 784a being shown) are then engaged in holes 772a, 772b, 774a and 774b of the U-shaped bracket 770 and in corresponding holes in the rear cross-member 202 of the fender portion 158 of the main frame 12, thereby securing the rear suspension frame 702 to the main frame 12 of the ATV 10.
[00396] At this stage, the left and right rear suspensions 704, 706 can be mounted to the rear suspension frame 702. In the illustrated embodiment, and referring now to Figures 100, 109 and 110, left rear suspension 704 comprises a lower A-arm 800 having an interior end 802 pivotably attached to the rear suspension frame 702 and an exterior end 804 attached to a spindle 812. An upper A-arm 806 has an interior end 808 attached to the rear suspension frame 702 and an exterior end 810 attached to spindle 812.
[00397] More specifically, and as best shown in Figures 109 and 110 the lower A-arm 800 has a generally U-shape and includes a front arm 814 provided with a bushing (not shown) at the interior end 802, a rear arm 816, also provided with a bushing (not shown) at the interior end 802, and a connecting portion 818 extending at the exterior end and receiving the spindle 812. Mounted to the connecting portion 818, in front of the location of the spindle 812, is a shock absorber mounting bracket 820.
[00398] The upper A-arm 806 has a general shape of a curved A, and comprises a front arm 822 and a rear arm 824. Both front and rear arms 822, 824 further include ends 808 used to connect upper arm 806 to main frame 12. A cross-member 826 extends between the front arm 822 and the rear arm 824 to increase rigidity.
[00399] To mount the left rear suspension 704 to the rear suspension frame 702 (best shown in Figure 97), the interior ends 802 of the front and rear arms 814, 816, of the lower A-arm 800 are attached to cross-members 726, 722, respectively, using threaded fasteners 830, 832 (shown in Figures 98 and 100) engaging holes 834a, 834b and 724a, 724b (holes 834a, 834b, 724a and 724b being best shown in Figure 103) and the bushings (not shown) found at the interior end 802 of the lower A-arm 800. Still referring to Figure 97, the interior ends 808 of the front and rear arms 822, 824 of the upper A-arm 806 are attached to cross-members 756, 780. A shock absorber 839 is attached to the rear left suspension 704. The shock absorber 839 includes a dampener 840, to which is mounted a coil spring 842. A lower end 844 of the dampener 840 is attached to the bracket 820 of the lower A-arm 800 while an upper end 846 is attached to the bracket 492 found at the junction of the upwardly extending left tube 110 and the upper tube 162 of the rear fender portion 158 of the main frame 12. [00400] Since right rear suspension 706 is essentially a mirror image of left rear suspension 704, it will be appreciated that the description of left rear suspension 704 also applies to right rear suspension 706, with proper adaptations.
[00401] As it will be appreciated by the person skilled in the art, rear suspension 700 can be used instead of rear suspension 24, without having to alter the remaining portions of the frame 12 of the ATV 10. This may prove advantageous in many instances, for instance by offering various rear suspensions in various market segments without requiring substantial changes to the rest of the vehicle, and without the need to substantially reconfigure the assembly line.
Further Alternate Rear Suspension Confiquration and Hitch Assembly
[00402] Figures 113, 1 14 and 115 show further features of a frame 35012 for the ATV 10, the main frame 35012 comprising a front portion 1610, a middle portion 1620 and a rear portion 1700 extending along a longitudinal axis Li- Li between a rear proximal end 1701 and a rear distal end 1799. The front portion 1610 is configured to receive left and right front shock absorbers (not shown in Figures 113 to 115) and the middle portion 1620 is configured to receive an engine (not shown in Figures 113 to 1 15). Figure 113 shows the rear portion 1700 of the main frame 35012 comprising a rear bumper 2000. For the purpose of the describing this and other embodiments, the bottom portions 35134, 35138 will sometimes be referred to as left and right “members” 35134, 35138 being understood that the terms “bottom portions” are used interchangeably with “members” to designate the same corresponding structures identified with the same reference numerals.
[00403] As best seen in Figures 1 13 to 1 17 the rear portion 1700 of the main frame 35012 comprises a left member 35134 adjacent the rear proximal end 1712, the left member 35134 extending upwardly from a left bottom end portion 1714 to a left top end portion 1716, and a right member 35138 adjacent rear proximal end 1722, the right member 35138 extending upwardly from a right bottom end portion 1724 to a right top end portion 1726.
[00404] As best seen in Figures 116 to 121 the left and right members 35134, 35138 also comprises left and right rear surfaces 1711 , 1721 and left and right bottom holes 1713, 1723 and left and right top holes 1715, 1725. Moreover, the left and right members 35134, 35138 comprise left and right bottom projections 1717, 1727 (best seen in Figure 121) extending forwardly along left and right bottom mounting axes LBMA, RBMA and left and right top projections 1719, 1729 extending forwardly along left and right top mounting axes LTMA, RTMA.
[00405] As best seen in Figure 122A, the left and right bottom projections 1717, 1727 comprise left and right inner walls 1750, 1752 defining left and right bottom channels 1751 , 1753 aligned with the left and bottom holes and the left and right top projections 1719,
1729 comprise left and right inner walls 1819, 1829 defining left and right top channels 1919, 1929 aligned with the left and right top holes (as best seen in Figure 120).
[00406] The rear portion 1700 of the frame 35012 also comprises a left transversal arm
1730 adjacent the rear proximal end 1712, the left transversal arm 1730 extending transversely between a left proximal end portion 1731 and a left distal end portion 1732, and a right transversal arm 1740 adjacent rear proximal end 1722, the right transversal arm extending transversely between a right proximal end portion 1741 and a right distal end portion 1742. The left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 further comprise left and right rear surfaces 1734, 1744, as best seen in Figures 1 15 to 117.
[00407] Referring to Figures 113 to 115 and 120, the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 are mounted to the left and right bottom end portion 1714, 1724 of the left and right members 35134, 35138. For instance, the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 are mounted to the left and right rear surfaces 1711 , 1721 of the left and right members 35134, 35138.
[00408] As best seen in Figures 114 to 118 the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 comprise left and right proximal ends 1732, 1742 extending longitudinally along the left and right bottom mounting axes LBMA, RBMA and forwardly up to the left and right members 35134, 35138.
[00409] As best seen in Figures 1 19 to 121 , the left and right proximal ends 1732, 1742 of the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 comprise left and right circular walls 1733, 1743 extending along the left and right bottom mounting axes LBMA, RBMA and defining left and right housings 1735, 1745. The rear portion 1700 of the frame 35012 also comprises left and right bushings 1737, 1747 adapted to be mounted in the left and right housings 1735, 1745. [00410] Moreover, referring to Figures 113 to 124, the rear portion 1700 of the main frame 35012 comprises a hitch receiver 1830 comprising a central projection 1831 extending rearwardly along the longitudinal axis L Li from a proximal end portion 1832 to a distal end portion 1833, left and right bottom protrusions 1840, 1850 extending transversely from the distal end portion 1833, and left and right top protrusions 1841 , 1851 extending transversely from the distal end portion 1833 (as best seen in Figures 118 and 121).
[00411] As best seen in Figures 118 and 121 , the central projection 1831 comprises exterior and inner walls 1834, 1835 and the inner wall 1834 of the central projection 1831 defines a housing 1836 for receiving an elongated portion of a hitch HI. As it is well known in the art, the elongated portion of the hitch HI may comprise a hole h and the central projection 1831 of the hitch receiver 1830 may comprise a hole 1837 for allowing locking of the hitch HI with respect to the hitch receiver 1830 with a locking bar LB comprising a removable lock L that is actuated with a key or with a pin (not shown) for instance. The central projection may extend along a length of between about 10 cm and about 20 cm.
[00412] As best seen in Figures 118, 119 and 124, the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 comprise left and right bottom apertures 1842, 1852 at respective distal ends and the left and right top protrusions 1841 , 1851 of the hitch receiver 1830 comprise left and right top apertures 1843 (not shown), 1853 at respective distal ends.
[00413] Referring to Figure 118, the left and right proximal ends 1732, 1742 of the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730,
1740 extend between the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 and the left and right members 35134, 35138.
[00414] Reverting to Figures 115-117, the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 are mounted to the left and right proximal end portions 1731 ,
1741 of the left and right transversal arms 1730, 1740 and the left and right top protrusions 1841 , 1851 of the hitch receiver 1830 are mounted to the left and right members 35134, 35138. More particularly, the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 are mounted to the left and right rear surfaces 1734, 1744 of the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 and the left and right top protrusions 1841 , 1851 of the hitch receiver 1830 are mounted to the left and right rear surfaces 1711 , 1721 of the left and right members 35134, 35138. [00415] Reverting to Figure 121 , the hitch receiver comprises a left flange 1845 between the left bottom and top protrusions 1840, 1841 , a right flange 1847 between the right bottom and top protrusions 1850, 1851 , a left bottom flange 1846 between the left bottom protrusion 1840 and the central projection 1831 and a right bottom flange 1848 between the right bottom protrusion 1850 and the central projection 1831 . The left and right flanges 1845, 1847 may comprise left and right rear walls 1854, 1856, extending upwardly from the left and right bottom protrusions 1840, 1850 and left and right top walls 1855, 1857, extending forwardly from the left and right rear walls 1854, 1856, up to the left and right top protrusions.
[00416] Each of the left and right flanges 1845, 1847 may be an L-shaped flange. Each of the left and right flanges 1845, 1847 and the left and right bottom flanges 1846, 1848 are provided to add rigidity to the left and right bottom protrusions 1840, 1850 and the left and right top protrusions 1841 , 1851 . Each of the left and right flanges 1845, 1847 and the left and right bottom flanges 1846, 1848 may extend up to the distal ends of the left and right bottom protrusions 1840, 1850 and the left and right top protrusions 1841 , 1851. The left and right rear walls 1854, 1856 of the left and right top protrusions 1841 , 1851 and the left and right bottom protrusions 1840, 1850 may comprise openings 1858 for reducing weight while still providing rigidity to the left and right bottom protrusions 1840, 1850 and the left and right top protrusions 1841 , 1851 .
[00417] As best seen in Figures 116, 118 and 119, the rear portion 1700 of the frame 35012 further comprises left and right bottom fasteners 12510, 12520 mounted in the left and right bottom apertures 1842, 1852 of the hitch receiver 1830, in the left and right bushings 1737, 1747 and in the left and right bottom holes 1713, 1723 of the left and right members 35134, 35138 and left and right top fasteners 12530, 12540 mounted in the left and right top apertures 1843, 1853 of the hitch receiver 1830 and in the left and right top holes 1715, 1725 of the left and right members 35134, 35138 for affixing the hitch receiver 1830 to the left and right members 35134, 35138 while allowing pivotable movement of the left and right transversal arms 1730, 1740 relative to the left and right bottom mounting axes LBMA, RBMA.
[00418] The left and right bottom fasteners 12510, 12520 may comprise left and right bottom bolts 12511 , 12521 comprising left and right distal threaded ends 12512, 12522 and left and right bottom nuts 12513, 12523 and the left and right top fasteners may comprise left and right top bolts 12531 , 12541 comprising left and right distal threaded ends 12532, 12542 and left and right top nuts 12533, 12543. As best seen in Figures 119 and 120 the left and right distal threaded ends 12512, 12522 of the left and right bottom bolts 12511 , 12521 extend forwardly outside the left and right bottom channels 1751 , 1753 of the left and right bottom projections of the left and right members and the left and right distal threaded ends 12532, 12542 of the left and right top bolts 12531 , 12541 extends forwardly outside the left and right top channels 1919, 1923 of the left and right top projections of the left and right members such that the left and right bottom nuts 12513, 12523 are mounted to the left and right distal threaded ends 12512, 12522 of the left and right bottom bolts 12511 , 12521 and the left and right top nuts 12533, 12543 are mounted to the left and right distal threaded ends 12532, 12542 of the left and right top bolts 12531 , 12541 for securing the hitch receiver 1830 onto the left and right members 35134, 35138 while allowing pivotable movement of the left and right transversal arms 1730, 1740 relative to the left and right bushings and the left and right bottom mounting axes upon upward or downward movement of the left and right wheels 22a, 22b mounted at the left and right distal ends 1732, 1742 of the left and right transversal arms 1730, 1740.
[00419] Moreover, as best seen in Figure 119, the left proximal end 1731 of the left transversal arm 1730 comprises a left-rear external circular wall 1733 facing the left bottom protrusion 1840 of the hitch receiver 1830 and the right proximal end 1741 of the right transversal arm 1740 comprises a right rear external circular wall 1743 facing the right bottom protrusion 1850 of the hitch receiver 1830. To allow free rotation of the left and right transversal arms 1730, 1740 with respect to the hitch receiver, the left and right rear circular external walls 1733, 1743 and the left and right bottom protrusions 1840, 1850 define left and right rear spaces therebetween. The left and right bushings 1737, 1747 may comprise left and right rear external circular walls 1754, 1756 being adapted to abut against the left and right bottom protrusions 1840, 1850 of the hitch receiver 1830 and left and right circular walls 1755, 1757 being adapted to be mounted in the left and right bottom apertures 1842, 1852 of the left and right bottom protrusions 1840, 1850.
[00420] It is therefore understood that the left and right proximal end portions 1731 , 1741 of the left and right transversal arms 1730, 1740 are pivotably mounted to the left and right members 35134, 35138 to allow pivotable movement of the left and right transversal arms 1730, 1740 upon upward or downward movement of the left and right wheels 22a, 22b while no torsional effort is transmitted to the hitch receiver 1830 that is independently mounted to the left and right members 35134, 35138.
[00421] Referring to Figure 113, the rear portion 1700 of the frame 35012 also comprises a left shock absorber 1760 adjacent the rear proximal end 1712, the left shock absorber 1760 extending upwardly from a left bottom end portion 1761 to a left top end portion 1762, and a right shock absorber 1770 adjacent rear proximal end 1722, the right shock absorber 1770 extending upwardly from a right bottom end portion 1771 to a right top end portion 1772. The left and right bottom end portions 1761 , 1771 of the left and right shock absorbers 1760, 1770 are mounted to the left and right transversal arms 1730, 1740 such that upon upward ordownward movement of the left and right wheels 22a, 22b, the left and right transversal arms 1730, 1740 pivot relative to the left and right members 35134, 35138 and the left and right shock absorbers 1760, 1770 are compressed or expanded.
[00422] Reverting to Figure 119, the left and right transversal arms may be left and right bottom transversal arms and the rear portion 1700 of the frame 35012 may comprise left and right top transversal arms 1780, 1790 adjacent the rear proximal end 1701. The left and right top transversal arms 1780, 1790 extend from left and right top proximal ends 1781 , 1791 to left and right top distal ends 1782, 1792 (not shown). The left and right top proximal ends 1781 , 1791 of the left and right top transversal arms 1780, 1790 are pivotably mounted to the left and right members 35134, 35138 and the left and right top distal ends 1782, 1792 of the left and right top transversal arms 1780, 1790 are mounted to the left and right wheels 22a, 22b. Upon upward or downward movement of the left and right wheels 22a, 22b the left and right bottom transversal arms 1730, 1740 and the left and right top transversal arms 1780, 1790 pivot relative to the left and right members 35134, 35138 and the left and right shock absorbers 1760, 1770 are compressed or expanded.
[00423] Referring to Figure 113, the left and right top end portions 1762, 1772 of the left and right shock absorbers 1760, 1770 may be mounted to left and right top members 35162, 35182 extending forwardly from the rear proximal end 1701 of the rear portion 1700 of the frame 35012.
[00424] Referring to Figures 113 and 114, the left and right members 35134, 35138 may be first left and right members, the left and right bottom transversal arms 1730, 1740 may be first left and right bottom transversal arms and the left and right top transversal arms 1780, 1790 may be first left and right top transversal arms, and the rear portion 1700 of the frame 35012 may comprise a second left member 1950 (not shown) spaced forwardly relative to the first left member 35134 and a second right member 1960 spaced forwardly relative to the first right member 35138, a second left bottom transversal arm 1970 extending transversely between a second left bottom proximal end portion 1971 (not shown) and a second left bottom distal end portion 1972, a second right bottom transversal arm 1980 extending transversely between a second right bottom proximal end portion 1981 and a second right bottom distal end portion 1982, a second left top transversal arm 1975 extending transversely between a second left top proximal end portion 1976 (not shown) and a second left top distal end portion 1977 (not shown), and a second right top transversal arm 1985 extending transversely between a second right top proximal end portion 1986 and a second right top distal end portion 1987.
[00425] The second left and right bottom proximal ends 1971 , 1981 of the second left and right bottom transversal arms 1970, 1980 are pivotably mounted to the second left and right members 1950, 1960 and the second left and right bottom distal ends 1972, 1982 of the second left and right bottom transversal arms 1970, 1980 are mounted to the left and right wheels 22a, 22b. The second left and right top proximal ends 1976, 1986 of the second left and right top transversal arms 1975, 1985 are pivotably mounted to the second left and right members 1950, 1960 and the second left and right top distal ends 1977, 1987 of the second left and right top transversal arms 1975, 1985 are mounted to the left and right wheels 22a, 22b.
[00426] Upon upward or downward movement of the left and right wheels 22a, 22b, the second left and right bottom transversal arms 1970, 1980 and the second left and right top transversal arms 1975, 1985 pivot relative to the second left and right members 1950, 1960 and the left and right shock absorbers 1760, 1770 are compressed or expanded.
Front Direction and Adjustment free power steering assembly
[00427] Turning now to Figures 125 to 134, an embodiment of a steering assembly 28 will now be described. In this embodiment, and as best shown in Figures 125 to 127 the steering assembly 28 comprises a steering column 900 having an upper end 902 and a lower end 904. Attached to the upper end 902 of the steering column 900 is a handlebar bracket 906 for mounting a handlebar clamp assembly 908, in which is clamped a handlebar 910 including controls for operating the ATV 10 (not shown in Figures 125 to 134).
[00428] Still referring to Figures 125 to 127, slightly below the handlebar bracket 906 is found a steering column mounting bracket 912 in the form of hemispherical bearing, for operatively attaching the upper end 902 of the steering column 900 to the main frame 12. More specifically, a pair of semi-spherical members (not shown) are attached to the upper end 902 of the steering column 900, the two semi-spherical members being received in a U-Shaped clamp member 917 attached to the cross-tube 118a of the main frame 12, via a pair of tubular members 916, 918 (shown in Figures 13 and 127). As it will be appreciated, the configuration of the steering column mounting bracket 912 allows rotational movement about the rotation axis R1-R1 of the steering column 900, whetherthe steering column 900 is perfectly aligned with main frame 12 or should there be a slight misalignment, for instance due to the assembly of the steering assembly 28 to the main frame 12 or because the main frame 12 and/or other components of the ATV 10 are subject to torsion and twisting during the operation of the ATV 10.
[00429] Returning to Figures 125 to 127, on the lower end 904 thereof, the steering column 900 is attached to a power steering assembly 920, in this case a Dynamic Power Steering (DPS). On a top end 922 thereof, the power steering assembly 920 comprises a male connector 921 (best shown in Figure 127) for receiving therein a splined lower end 904 of the steering column 900. Extending on a bottom end 924 of the power steering assembly 920 is a shaft 926, the shaft 926 having a lower end 928 provided with a hemispherical bearing 930 for attaching the power steering assembly 920 to the main frame 12, and a pitman arm 932 attached to the shaft 926. Extending between the top end 922 and the bottom end 924 of the power steering assembly 920 is a casing 934 for housing the internal parts of the power steering assembly 920, the casing 934 being mounted to the main frame via a pair of C-shaped brackets 936, 937 secured to the bottom end 924 of the steering assembly 920, as it will become apparent below.
[00430] Turning now to Figure 128, the pitman arm 932 is configured for operatively receiving left and right tie rods 940, 942, and to collaborate with a pair of stoppers 944, 946 extending from the main frame 12 and configured to restrict the turn angle of the front wheels 16a, 16b when the front suspension 18 of the ATV 10 is in a showroom position (shown in Figures 125 to 130). More specifically, and still referring to Figure 128, the pitman arm 932 has a generally keyhole shape and comprises a hub 948 attached to the shaft 926 of the power steering assembly 920 and trapezoidal mounting plate 950 extending radially from the hub 948, towards the rear of the ATV 10. The trapezoidal mounting plate 950 comprises a first end 952 in contact with the hub 948, two side ends 954, 956 extending from the first end 952, away from one another, and a gently curved rear end 958. The side ends 954, 956 of the trapezoidal plate 950 define angles adapted to match left and right stoppers 944, 946 extending from the frame 12 of the ATV 10, on each side of the left and right side 954, 956 of the trapezoidal mounting plate 950. When the suspension 18 of the ATV 10 is in the showroom position, and the steering assembly 28 is in a neutral steer position (/.e. the wheels 16a, 16b of the ATV 10 are positioned to move in a straight ahead direction) an equal space is defined between each of the left and right side ends 954, 956 of the plate 950 and the left and right stoppers 944, 946. When the steering assembly 28 is steered in a full-left steer (best shown in Figure 126, 128, 129 and 130), the right side end 956 of the trapezoidal plate 950 abuts against the right stopper 946, thereby preventing further steering of the front wheels 16a, 16b toward the left. Likewise, when the steering assembly 28 is steered in a full right steer (not shown), the left side end 954 of the trapezoidal plate 950 abuts against the left stopper 944, thereby preventing further steering of the front wheels 16a, 16b toward the right. As it will be appreciated, the size, shape and position of the trapezoidal plate 950, as well as of the stopper 944, 946 extending from the main frame 12, can be configured to reduce the stress on the various joints of the steering assembly 28 while allowing a certain degree of freedom to steer the ATV 10 in left and right directions.
[00431] Connecting the knuckles 300 of the left and right wheels 16a, 16b to the pitman arm 932 are the left and right tie rods, 940, 942 respectively (best shown in Figures 126 and 128). Left tie rod 940 comprises a right end 962, mounted to the pitman arm 932 via a spherical bushing or ball joint 964, and a left end 960 attached to the left knuckle 300, also via a spherical bushing 966. Likewise, the right tie rod 942 comprises a left end 970, attached to the pitman arm 932 via a spherical bushing 972, and a right end 974 attached to the knuckle 300 of the right wheel 16b (not shown in Figures 127 and 128), also via a spherical bushing 976.
[00432] Turning now to Figures 129 and 131 , in the illustrated embodiment, the exterior end 310, corresponding to second end 310 of Figure 59, of the lower A-arm 296 is provided with a stopper 980 extending from the rear arm of lower A-arm 296, proximate to the junction with the front arm thereof. As best shown in Figure 129, the stopper 980 extends outwardly (/.e. in a left, sideways direction). The stopper 980 comprises a slightly inclined abutment face 982, configured to collaborate with a knuckle projection 990 to restrict the turn movement of the left wheel 16a when the suspension moves from a showroom position (shown in Figures 125 to 130) to a full-droop position (shown in Figures 131 to 133) or a full-bump position (not shown) and the steering assembly 28 is in a full-steer position toward the left, as it will become apparent below.
[00433] The knuckle projection 990 extends rearwardly from the knuckle 300 and comprises a slightly inclined interior face 992. The angle of the interior face 992 of the knuckle projection 990 relative to a vertical plan matches the angle of the abutment face 982 of the stopper 980. When the steering assembly is in a full-steer position in one direction (e.g. toward the left, as shown in Figures 131 to 133), and the suspension moves from a showroom position (in which the right side 956 of the trapezoidal plate 950 of the pitman arm 932 abuts the right stopper 946, as best shown in Figure 130) to a full-droop position (or a full-bump position as shown in Figure 133), the slightly inclined face 992 of the knuckle projection 300 gradually engages the abutment face 982 of the stopper 980 found on the lower A-arm 296. This engagement forces the steering assembly 28 to rotate towards the neutral (straight ahead) steering position of the steering assembly 28 and causes the right end 956 of the trapezoidal plate 950 of the pitman arm 932 to move slightly away from the right stopper 946 (shown in Figure 133). As it will be appreciated, the stopper 980 and knuckle 300 configuration collaborate to slightly reduce the degree of freedom of the steering assembly 28 in one direction or the other, which in turn contributes to reduce the stress on various joints of the steering assembly 28 during the operation of the ATV 10, especially when the steering assembly 28 is in full steer position and the front suspension is called to move between the showroom, full droop and/or full-bump positions. As described above, the left and right front suspension subassemblies 292, 294 being mirror images of one another, a similar description of stopper 980 and knuckle projection 990 also applies to right front suspension subassembly 294, with proper adaptations.
[00434] As it will be appreciated, the assembly of the power steering assembly 920 (in this illustrated embodiment, a DPS) to the main frame 12 may be challenging in some instances. Indeed, the rotation axis R1-R1 of the steering column 900 and of the male connector 921 (shown in Figure 127) of the power steering assembly 920 must be aligned within a certain degree of tolerance, since a misalignment can lead to premature damage to the power steering assembly 920. As such, manufacturers tend to require that the assembly of power steering to the frame ofthe ATV follow a specific sequence for securing the various fasteners, which can prove challenging because the assembly line workers or repair technicians may omit to follow this specified sequence.
[00435] Accordingly, in one embodiment, best illustrated in Figure 134, the power steering assembly 920, and the brackets for mounting the same to the main frame 12 of the ATV 10 are configured to slightly deform when the power steering assembly 920 is mounted to the main frame 12, such that when the lower end 904 of the steering column 900 engages the male connector 921 (best shown in Figure 127), the power steering assembly 920 is forced into a proper alignment with the axis of the steering column 900, and persistently maintains such an alignment. In other words, the relative flexibility of the assembly of the power steering assembly 920 and the bracket for mounting the same to the main frame 12 of the ATV 10 contribute to increase the manufacturing tolerances and avoid the need for a specific sequence of assembly of the fasteners used to secure the power steering to the frame.
[00436] More specifically, in the illustrated embodiment of Figure 134, the main frame 12 of the ATV 10 is provided with the pair of angular left and right tube members 1001 , 1003 connecting left and right front upwardly extending tubes 108 and 112 to the crossmember 147. Proximal to cross-member 147, and extending between the left and right tube members 1001 , 1003, is a lower steering assembly mounting plate 1000 including a main portion 1002 for receiving the lower end 928 of pitman arm 932, and left and right portions 1004, 1006 extending angularly from the main portion 1002, for securing the lower steering mounting plate 1000 to the left and right tube members 1001 , 1003, respectively. Furthermore, in the illustrated embodiment, left and right portions 1004, 1006 of the mounting plate 1000 define stoppers 944 and 946, respectively.
[00437] As best shown in Figure 134, the mounting plate 1000 is provided with a circular hole 1005, configured to receive the spherical bearing 930 at the lower end 928 of the pitman arm 932 mounted to shaft 926 extending from the power steering assembly 920, as well as a plurality of holes 1007a-1007c for receiving therein a corresponding plurality of threaded fasteners 1009a-1009c for securing the C-shaped brackets 936, 937 to the mounting plate 1000. When the steering assembly 28 is assembled to the main frame 12, the C-shaped brackets 936, 937 each have an upper end 1010, mounted to the casing 934 of the power steering assembly 920, at the lower end 924 thereof, using threaded fasteners 1011 a-1011 c, and a lower end 1012 secured to the mounting plate 1000 by way of threaded fasteners 1009a-1009c. A generally vertical plate portion 1014 extends between the upper end 1010 and the lower end 1012 of the C-shaped bracket 936, the main portion 1014 being configured to allow an elastic deformation of the C-shaped bracket 936, which elastic deformation is induced in case of misalignment of the power steering assembly 920 with the main frame 12. As such, the C-shaped bracket, along with the spherical bearing 930 at the lower end 928 of shaft 926 and the spherical bracket 912 proximate to the upper end 902 of the steering column 900, allow for a degree of misalignment of the power steering assembly 920 relative to the main frame 12 while maintaining the operation of the steering assembly 28 and contributing to reduce damages to the power steering assembly 920 that may be caused by such a misalignment.
Airbox confiquration
[00438] For feeding the engine 14 with clean air, the ATV 10 is provided with an airbox 7200. In one embodiment, illustrated in Figures 135 to 142, the airbox 7200 is generally V-shaped (when seen from the top in Figure 140 or bottom in Figure 141) and comprises, as best shown in Figures 138 and 139, a V-shaped base portion 7202 and a V-shaped top portion 7204. V-shaped base portion 7202 and a V-shaped top portion 7204 define a housing 7206 which houses air filter 7208, as will be described in detail below. Referring to Figure 140, the housing 7206, defined by the base portion 7202 and the top portion 7204, comprises a left intake section 7210, a right outtake portion 7212, each having front ends 7214, 7216 respectively, and rear ends 7218, 7220 respectively. Extending between the rear ends 7218, 7220 of the left intake portion 7210 and the right outtake portion 7212, is a conduit portion 7222. Further, at the rear end 7220 of the right outtake portion 7212 is an outtake conduit 7222, for operatively connecting the airbox 7200 to the engine 14 via a pipe (not shown). Between the left intake portion 7210 and the right outtake portion 7212, a space 7226 is provided for allowing the passage of the steering assembly 28 as is best shown in Figure 141 .
[00439] Returning to Figures 138 and 140, the left intake section 7210 of the housing 7206 comprises a bottom pocket wall 7230 defined by the left portion of the base section 7202. Received in the bottom pocket wall 7230 is a first air intake conduit 7232. The first intake conduit 7232 is curved and defines an arc of a circle, and comprises a first end 7234, and a second end 7236, which lower end 7236 of the first intake conduit 7232 is located below the conduit portion 7222 of the housing 7206.
[00440] The left intake section 7210 of the housing 7206 also comprises a top pocket wall 7240 defined by the left portion of the top portion 7204, and an intake conduit 7242. When the top portion 7204 of the housing 7206 is mounted to the base portion 7202, the conduit 7242 of the top portion 7204 is in fluid communication with the first intake conduit 7232 of the base portion 7202, and allows ambient airto enterthe left portion of the airbox 7200.
[00441] Operatively mounted at the rear end 7219 of the left portion 7210, in fluid connection with the conduit portion 7222 of the airbox 7200, is the air filter 7208. In one embodiment, the air filter 7208 is threadably mounted to the housing 7206 via a threaded conduit 7243 mounted to the top portion 7204, in registry with the conduit portion 7222 (see Figure 142). The air filter 7208 properly mounted to the top portion 7204 of the airbox 7200 is located above the second end 7236 of the first intake conduit 7232 when the base and top portions 7202, 7204 are assembled together, such that any unwanted, heavier material entering the conduit 7242 of the top portion 7204 and carried through the first intake conduit 7232 of the base 7202 will remain in the bottom pocket wall 7230 of the airbox 7200 because of gravity, rather than being conveyed toward the air filter 7208.
[00442] To service the air filter 7208, an opening 7250 is defined in the top pocket wall 7240. Opening 7250 is sealed closed by a gasket 7252 and a cover 7254 using a plurality of clamps 7256a-7256d. To service the air filter 7208 and remove material that may be found in the left portion 7210 of the housing 7206, the clamps 7256a-7256d are opened and the cover 7254 is removed, thereby giving access to the air filter 7208 and the left portion 7210 of the housing 7206. When service is completed, the gasket 7252 and cover 7254 are properly repositioned, and the clamps 7256a-7256d are secured to maintain the cover 7254 in position.
[00443] Extending from the rear end 7220 of the right portion 7212, and attached to the bottom pocket wall 7260, is a generally cylindrical second intake conduit 7262. The second intake conduit 7262 has a rear end 7264 operatively connected to the conduit portion 7222 of the housing 7206, and a front end 7266 extending toward the front end 7216 of the right, outtake portion 7212. Located below the second intake conduit 7262 is the outtake conduit 7224.
[00444] The conduit portion 7222 of the housing 7206 operatively connects the air filter 7208 to the second intake conduit 7262, and comprises a lower conduit portion 7270 defined by the base portion 7202 and an upper conduit portion 7272 defined by the upper portion 7204 of the airbox 7200. When the upper portion 7204 of the airbox 7200 is secured to the base portion 7202, the upper and lower portions 7272, 7270 of the conduit portion 7222 define somewhat of a curved pipe.
[00445] During the operation of the ATV 10, fresh air required for the operation of the engine 14 enters the intake conduit 7242 and travels through the first intake pipe 7232, moving from the first end 7234 thereof to the second end 7236. When the fresh air reaches the second end 7236, heavier debris and/or water that may be prone to enter the airbox 7200 during the operation of the ATV 10 fall to the bottom pocket wall 7230 and accumulate therein while air and lighter particles are conveyed towards the air filter 7208. When the fresh air and lighter particles reach the air filter 7208, the lighter particles are filtered out and the filtered air reaches the conduit portion 7222 of the airbox 7200. At that point, the filtered air will travel through the conduit portion 7222 to reach the second intake conduit 7262 and will be directed toward the outtake conduit 7224 to be conveyed to the engine 14. [00446] Returning to Figure 139, to assemble the airbox 7200, the base portion 7202 is joined to top portion 7204 using threaded fasteners, clips, glue and the like. The air filter 7208 can then be positioned in the housing 7206 and the opening 7250 closed using gasket 7252 and cover 7254 by way of clamps 7256a-7256b. As best shown in Figures 135 and 136, the airbox 7200 is mounted to the left and right upper tubes 104, 106 of the main frame 12, proximal to cross-member 118a, using threaded fasteners. In this location, the space 7226 defined between the left and right portions 7210, 7212 of the airbox provides room for receiving the steering column 900 of the steering assembly 28.
Alternate Airbox and Service Center
[00447] Referring now to Figures 143 to 159, there is shown an embodiment of an ATV similar to ATV 10, comprising an improved service center 3100 and an improved airbox 3200 accessible through the service center 3100.
[00448] As best shown in Figures 143 to 147, the service center 3100 is located in the hood area of the ATV 10, in front of a steering device 3128 (e.g., handlebar 910). The service center 3100 is formed from several surrounding body panels 3102. A removable top cover 3110 covers the body panels 3102 to close the service center 3100 and to cover and protect the elements therein. In the illustrated embodiment, the service center 3100 regroups and provides access to the airbox 3200, an air entry or inlet 3203 leading into the airbox 3200, a coolant bottle 3010, a fuse box 3104 and a CVT air entry 3020. In one embodiment, the top removable cover 3110 may be configured for easy removal, for example using toolless % turns at the rear and a toe-in at the front. Other easy removal configurations for the top removable cover 3110 will be apparent, including without limitation the use of snap engagement means, hoop and loop fasteners, magnets and the like. The cover 3110 may further comprise additional components such as electrical components, a display for displaying information concerning the vehicle systems, communication devices to the driver and/or electric outlets 3106 such as a 12v female plug. Wires 3108 supplying such components with power and/or data can extend from the ATV to the cover 3110 and comprise such a length as to allow the cover 3110 to be detached and placed to one side to access the components within the service center 3100 without having to disconnect the wires. Alternatively, the wires can be detachably connected to the ATV and or to the cover 3110, allowing the wires to be disconnected and the cover 31 10 to be removed.
[00449] As it will be apparent, the fact that the airbox 3200, the air entry or inlet 3203 leading into the airbox 3200, the coolant bottle 3010, the fuse box 3104 and the CVT air entry 3020 are all located in the service center 3100, in front of the steering assembly 28 provides access to all these components without the need to dismantle other portions of the ATV, for instance cowlings or the seat. This configuration of service center 3100 proves to be particularly useful to carry out maintenance of an air filter 3220. Indeed, as opposed to prior art ATVs which included airboxes extending partially rearwardly of the handlebar and under the seat, and which required disassembling at least a significant portion of the ATV or the seat to maintain or replace the ATV air filter, the service center 3100 provides access to airbox 3200, which is also configured to allow accessing and/or replacing the air filter 3220 via the service center 3100.
[00450] More particularly, in the embodiment illustrated in Figures 146 and 147, under the removable top cover 3110 of the service center 3100, is a removable airbox cover 3212 covering an opening 3210 into the airbox 3200 that can be removed to get access to the air filter 3220. The air filter 3220 can be removed from the airbox 3200 through the opening 3210 and the service center 3100.
[00451] Referring now to Figures 150 to 155, the airbox 3200 generally comprises a housing 3120 comprising a top portion 3201 and a bottom portion 3202, the top portion 3201 being configured to receive an air entry 3203. The top portion 3201 further comprises the opening 3210 and is configured to receive the cover 3212 to abut the opening 3210. Air leaves the airbox 3200 towards an engine, such as engine 3050, through an engine air entry 3900.
[00452] Referring to figures 146 and 147, the airbox 3200 is generally located in front of the steering device (e.g., handlebar 910) of ATV 10. The airbox 3200 presents several advantages over airboxes of the prior art, including a shorter air intake path, greater ease of maintenance and the possibility of accessing the interior of the airbox 3200, including the air filter 3220, through the service center 3100.
[00453] The airbox cover 3212 is configured to abut the opening 3210 and to be removably secured to the top portion 3201 of the airbox 3200. The airbox cover 3212 is held in place with securing means 3211 configured to be manipulated and removed without the use of tools, for example by one or more over-center clips. The cover 3212 further comprises at least one protrusion 3213 extending into the airbox 3200. The protrusions 3213 may extend substantially vertically, or diagonally, or substantially parallel to the walls of the housing. The protrusions 3213 may further comprise notches, recesses or indentations 3214, the advantages of which will be apparent below. [00454] Referring now to Figures 155 to 159, the airbox 3200 is configured to receive an air filter 3220 through opening 3210. The air filter 3220 extends between a distal end 3221 , situated distally from engine air entry 3900, and a proximal end 3222, situated proximally to the engine air entry 3900. When the air filter 3220 is installed in the airbox 3200, the recesses or indentations or notches 3214 are configured to abut and engage at least a portion of the distal end 3221 , thereby holding the air filter 3220 in position. The airbox 3200 may further comprise a Helmholtz resonator 3230, configured to reduce noise and vibration, such as engine noise and cavitation vibrations, from the engine and from other components of the ATV 10. This is advantageous as it increases the comfort of a user of ATV 10 while ATV 10 is in operation.
[00455] Figure 158 shows the positioning of the features previously described within the airbox 3200 when the airbox 3200 is installed and closed. Air filter 3220 extends from engine air entry 3900 towards the front of airbox 3200, and is configured to connect at its distal end 3221 to means for conveying air from the air intake 3203 to the air filter. Airbox cover 3212 is secured to the airbox top portion 3201. Protrusions 3213 extend into the airbox body and recesses 3214 engage the top portion of the distal end 3221 of air filter 3220. The distal end 3221 is thereby sandwiched between the protrusions 3213 and, for example, Helmholtz resonator 3230, or any other feature suitable to engage a bottom portion of the distal end 3221 of filter 3220 to hold it in position in cooperation with protrusions 3213.
[00456] Referring now to Figures 157 to 159, an advantageous way of removing filter 3220 from airbox 3200 is shown. When installed, as shown in Figure 157, filter 3220 abuts engine air entry 3900. The airbox cover 3212 is removed, leaving opening 3210. Filter 3220 is displaced from engine air entry 3900 (shown in Figure 158). Engine air entry 3900 may be configured to engage the air filter 3220 by means of a protruding conduit 3901 . Other means of connecting and/or securing an air filter 3220 to engine air entry 3900 will be apparent. Upon disengaging from the engine air entry 3900, filter 3220 may be at least partially rotated to a more vertical orientation for ease of removal through the opening 3210 (moving for the position shown in Figure 158 to the position shown in Figure 159). As best shown in Figure 159, the air filter 3220 is then removed through opening 3210, located within service center 3100 of ATV 10.
Alternate radiator positioning and cover
[00457] Referring now to Figures 160 to 171 , an ATV 5100 according to another is shown. In this embodiment, the ATV 5100 is configured to be operated on various terrains and in a variety of conditions, and in certain depths of water, for instance by crossing a stream and/or in muddy conditions, for example after heavy rainfalls, during a thaw period, in wetlands, or otherwise in conditions that favour a muddy terrain. It is therefore advantageous to provide features allowing for easy maintenance of key components in such conditions, to improve vehicle performance and user comfort. The ATV 5100 may comprise components such as frames, engines, bumper assemblies and other components as described above. In particular. ATV 5100 also comprises a radiator 5200 (see Figures 163, 164 and 166) positioned forwardly from the seat 5110 and steering device 5120 (i.e., handlebar 910) and at an elevated position, substantially level with the handlebar 910 and the seat 5110. In this embodiment, the radiator 5010 is positioned at an elevated position with respect to the engine and frame components, generally above the front wheels, such that the radiator is at a higher distance from the ground and from the terrain as compared to traditional ATVs.
[00458] In the illustrated embodiment, the radiator 5200 is covered by a radiator cover assembly 5202 comprising a top cover 5210 and side portions 5212. The cover 5210 comprises air inlet means 5211 on a front-facing side 5205 which allow the cover 5210 to provide oncoming air with access to the radiator. The side portions 5212 rise substantially vertically from the wheel fenders 5213, on each side of the cover 5210 such that the generally vertical side portions 5212 and the cover 5210 create a ram air effect, ramming oncoming air onto the radiator 5200. Referring to Figures 170 and 171 , the cover 5210, when the ATV is in use, allows airflow 5300 to enter a space between the cover 5210 and the radiator 5200. The pressure exerted by the forward motion of the ATV 5100 rams the airflow 5300 over the radiator 5200, improving its performance.
[00459] In one embodiment, the cover 5210 may be pivotably attached to the radiator 5200 or to another structural element of the ATV 5100 in proximity to the radiator 5200. A pivotable attachment of the cover 5210 is advantageous in that it allows for easy access and cleaning of the radiator 5200. For example, referring to Figures 163 to 165 and 167, the cover 5210 may pivot about pivot points 5214, situated proximate to the air inlets 5211 . For ease of opening, the cover 5210 may comprise latching means 5215, for example latches, situated at an end proximate the user of the ATV 5100 with respect to the pivot points 5214 (see Figures 164 and 167). The latches 5215 may be made from any suitable material, for example rubber, and secure the cover 5210 in a closed position when the ATV 5100 is in use. By pivoting upward and forward, the cover 5210 gives a user of the ATV 5100 easier access to the radiator to wash and/or remove debris that could be blocking the radiator. [00460] In some embodiments, the cover 5210 may comprise additional elements to enhance the user’s experience or provide easy access to necessary tools or information. For example, referring to Figures 168 and 169, the cover 5210 may further comprise, situated within its inner portion (or inner face) 5401 , a toolkit 5400, which may comprise an assortment of useful tools such as screwdrivers, pliers, wrenches and the like. In particular, the toolkit may comprise tools matching the sizes and other characteristics of components of ATV 5100. The toolkit 5400 may be secured to the inner portion of the cover 5210 by any suitable means. For instance, it may be secured by means of a pivotable bar or latch 5410. Other securing means will be apparent.
Method of transporting
[00461] With reference to Figures 177 and 178, packing the ATV 10 for shipment will now be described in accordance with one embodiment. In this embodiment, the ATV 10 is packed according to a method described in United States Provisional Patent Application No. 62/538,922 and United States Patent Application No. 15/681 ,943, both entitled “Method of Packing a Vehicle in a Crate for Shipment,” filed on July 31 , 2017 and on August 21 , 2017, respectively, the entirety of which is incorporated herein by reference.
[00462] In this embodiment, the ATV 10, is packed and shipped in a crate 1450, illustrated in Figures 177 and 178. The crate 1450 is sized to be stacked on top of two identically sized crates 1450, where the height of the three crates 1450, stacked one on top of the others, does not exceed a predetermined maximum shipping height. In the present implementation, the crates 1450 once stacked are sized not to exceed a maximum shipping height of 105 inches (about 2667 mm). It is contemplated that the crates 1450 could be sized to comply with different or multiple specific restrictions for different modes of shipment or changes in transport regulation. In one embodiment, the crate 1450 therefore has an exterior height H2 (see Figure 178) which is equal to or less than an internal height of 105 inches (2667 mm) of a shipping container. In one embodiment, the exterior height H2 of each crate 1450 has a height of 34.4 inches (874.125 mm) such that three crates 1450 stacked onto one another have a total exterior height of 103.24 inches (2622.30 mm).
[00463] The crate 1450 comprises a steel frame 1452 on which is wrapped a plastic cover (not shown in Figures 177 and 178). The steel frame 1452 comprises a bottom frame portion 1460 comprising left and right frame members 1454, 1456 (only left frame member 1454 being shown in Figure 177), each comprising a front end 1458 and a rear end 1462. The bottom frame portion 1460 also comprises a front cross-member 1464 extending between the left and right frame members 1454, 1456, at the front ends 1458 thereof, and a rear cross-member 1466, also extending between the left and right frame members 1454, 1456, but at the rear ends 1462 thereof. The bottom frame portion 1460 also includes a pair of rectangular tube members 1470, 1472, extending between the left and right frame members 1454, 1456. Rectangular tube members 1470, 1472 are configured to be used by a forklift to move the crate 1450, as well as the ATV 10 and the crate 1450 when the ATV 10 is packed therein. The tubes 1470, 1472 extending across the width of the bottom frame portion 1460 further provides weight bearing surfaces on which most of the weight of the ATV 10 will rest when the ATV 10 is fully packed in the crate 1450, as will be described in more detail below. Provided at the front and rear ends 1458, 1462, as well as in an intermediate location 1474 between the front and rear ends 1458, 1462, are brackets 1476, 1478 and 1480.
[00464] The crate 1450 also includes left and right side wall frame portions 1482, 1484, and a top frame portion 1486. The left and right side wall frame portions 1482, 1484 each comprise a front frame member 1488, a rear frame member 1490 and an intermediate frame member 1492, all extending upwardly and vertically from the left and right frame members 1454, 1456, at the front end 1458, rear end 1462 and intermediate location 1474, respectively, and are attached to left and right frame members 1454, 1456 via brackets 1476, 1478 and 1480.
[00465] The top frame portion 1486 comprises longitudinal frame members 1500, 1502 having a front end 1504 and a rear end 1506, the top longitudinal frame member 1500, 1502 having generally the same length as frame members 1454, 1456 of the bottom frame portion 1460. Top frame portion 1486 also includes a front cross-member 1508, a rear cross-member 1510 and a pair of intermediate cross-members 1512, 1514. Bracket 1520, 1522 and 1524 are configured for securing the top frame portion 1486 to upper ends of front frame member 1488, intermediate frame member 1492 and rear frame member 1490 of the left and right side wall frame portions 1482, 1484. When the frame portions are assembled, the exterior of the frame has a height H2 and an internal height H3
[00466] The ATV 10, when at rest and ready to use (/.e. in a showroom configuration), has a full ATV height Hi measured from the ground up to the top of the steering assembly 28, as is illustrated in Figure 6. By comparing the full ATV height Hi to the maximum internal height H3, it can be seen that the ATV 10 cannot be packed into the crate 1450 in a configuration where the ATV is at its full ATV height Hi. [00467] In order to pack the ATV 10 in the crate 1450 according to the method of the present embodiment, the ATV 10 is compressed into a packing configuration by compressing the front and rear suspensions 18 and 24 or 700, and the handlebars 910 are lowered, such that the ATV 10 has a packing height H4. The ATV 10 is shown in the packing configuration inside the crate 1450 in Figures 177 and 178. It should be noted that the height H4 from the ground to the top of the ATV 10, when in the packing configuration, may not necessarily be less than the maximum internal height H3 of the crate 1450. Compression of the front and rear suspensions 18 and 400 or 700 to bring the ATV 10 into the packing configuration will be described in more detail. The front and rear suspensions 18 and 400 or 700 are compressed using four tie-down straps (not shown), each tie-down strap in this embodiment being preferably a ratchet type tie-down strap, such as those described in United States Provisional Patent Application No. 62/538,922 and United States Patent Application No. 15/681 ,943, both entitled “Method of Packing a Vehicle in a Crate for Shipment,” filed on July 31 , 2017, and on August 21 , 2017, respectively, the entirety of which is incorporated herein by reference.
[00468] The ATV 10 is in the packing configuration when lower left and right tubes 100, 102 of the main frame 12 of the ATV 10 abuts the rectangular tubes 1470, 1472 of the crate 1450. When the lower left and right tubes 100, 102 of the main frame 12 abut the rectangular tubes 1470, 1472 of the crate 1450, height H4 needs to be equal to or less than the maximum internal height H3 of the crate 1450. Further, when the ATV is in the packing configuration, the weight of the ATV 10 generally rests on the rectangular tubes 1470, 1472 rather than on the wheels 16a, 16b, 22a, 22b. As such the tires of the front and rear wheels 16a, 16b and 22a, 22b could, in some instances, be deflated without risking damage to the tires on the wheels 16a, 16b and 22a, 22b as they may extend below frame members 1454, 1456. When the ATV 10 is in the packing configuration, the front and rear suspensions 18 and 24 or 700 also abut suspension stoppers of the ATV 10 (not shown).
[00469] Once the ATV 10 is in the packing configuration on the bottom frame portion 1460 of the crate 1450, it can be attached to the bottom frame portion 1460 by connecting a plurality of plastic straps (not shown) or other securing means.
[00470] Once the ATV 10 is placed on the bottom frame portion 1460 and in the packing configuration, the crate 1450 can be closed by assembling the side walls portions 1482, 1484 and the top wall portion 1486 to the bottom frame portion. Alternatively, the side walls portions 1482, 1484 and the top wall portion 1486 can be assembled together first, and then connected to the bottom wall portion 1460, although this may not always be the case. Once the frame 1452 of the crate 1450 is assembled, it can be wrapped with a plastic material or any other suitable material to protect the ATV 10 during shipment.
[00471] The above description of the variants, examples or embodiments should not be interpreted in a limiting manner since other variations, modifications and refinements are possible within the scope of the present invention. Accordingly, it should be understood that various features and aspects of the disclosed variants or embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. For example, and without limitation, any individual element of the described variants or embodiments may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to a skilled person in the art, and alternative elements that may be developed in the future, such as those that a skilled person in the art might, upon development, recognize as an alternative. The scope is defined in the appended claims and their equivalents.

Claims

1 . A frame for an all-terrain vehicle, the frame comprising a main frame extending along a longitudinal axis and comprising a front portion, a middle portion and a rear portion, wherein the front portion is configured to receive a portion of a front suspension, wherein the rear portion is configured to receive a portion of a rear suspension, and wherein the middle portion comprises: a left bottom longitudinal member extending from a left bottom proximal end portion through a middle portion to a left bottom distal end portion; a right bottom longitudinal member extending from a right bottom proximal end portion through a middle portion to a right bottom distal end portion; a left top longitudinal member extending from a left top proximal end portion through a middle portion to a left top distal end portion; and a right top longitudinal member extending from a right top proximal end portion through a middle portion to a right top distal end portion; wherein a first distance is defined between one of the left top longitudinal member and the left bottom longitudinal member or the right top longitudinal member and the right bottom longitudinal member; wherein a second distance is defined between the other of the left top longitudinal member and the left bottom longitudinal member or the right top longitudinal member and the right bottom longitudinal member, the first and second distances being measured at corresponding left and right positions along the longitudinal axis; wherein the first distance is greater than the second distance; wherein the left and right bottom longitudinal members and the left and right top longitudinal members define therebetween an engine compartment adapted to receive engines of different sizes; and wherein a space is defined above the other of the left and right top longitudinal members being at the second distance.
2. The frame of claim 1 , wherein the space is defined between the one of the left and right top longitudinal members being at the first distance and the other of the left and right top longitudinal members being at the second distance.
3. The frame of claims 1 or 2, wherein the first distance is defined between the right top longitudinal member and the right bottom longitudinal member and the second distance is defined between the left top longitudinal member and the left bottom longitudinal member.
4. The frame of claim 3, wherein the space is defined between the left and right top longitudinal members.
5. The frame of any one of claims 1 to 4, wherein the space is adapted to receive at least one component of the all-terrain vehicle.
6. The frame of claim 5, wherein the at least one component is selected from a group comprising a steering assembly, steering cables, an airbox, an air filter, a storage compartment and a battery.
7. The frame of any one of claims 4 to 6, wherein the middle portion comprises: a front top cross-member extending between the left top distal end portion of the left top longitudinal member and the right top distal end portion of the right top longitudinal member, the front top cross-member comprising left and right end portions, and a left longitudinal member extending outwardly sidewardly from the left end portion of the front top cross-member or from the left top distal end portion of the left top longitudinal member and downwardly to a left bottom end portion, and wherein the space is defined above the left top longitudinal member and therebetween the left longitudinal member and the right top longitudinal member.
8. The frame of claim 7, wherein the middle portion comprises a front left member extending upwardly from the left bottom longitudinal member up to the front top crossmember and a front right member extending upwardly from the right bottom longitudinal member up to the front top cross-member.
9. The frame of claim 7 or 8, wherein the middle portion comprises a right longitudinal member extending outwardly sidewardly from the right proximal end portion of the front top cross-member or from the right top proximal end portion of the right top longitudinal member and downwardly to a right bottom end.
10. The frame of any one of claims 1 to 9, wherein the first distance is between about 65 cm and about 45 cm and wherein the second distance is between about 60 cm and about 40 cm.
11 . The frame of any one of claims 8 to 10, wherein the middle portion comprises: a first lower cross-member connecting the left bottom longitudinal member and the right bottom longitudinal member at the left and right bottom proximal ends; and a second lower cross-member comprising left and right end portions, and extending between the left bottom longitudinal member and the right bottom longitudinal member at the middle portion of the left and right bottom longitudinal members, wherein the left end portion of the second lower cross-member connects the front left member extending upwardly and the left bottom longitudinal member, and wherein the right end portion of the second lower cross-member connects the front right member extending upwardly and the right bottom longitudinal member.
12. The frame of any one of claims 7 to 1 1 , wherein the front top cross-member is a first top cross-member and wherein the middle portion comprises a second top crossmember connecting the first left and right top longitudinal members at respective left and right middle portions of the first left and right top longitudinal members.
13. The frame of claim 12, wherein the space is defined above the second top crossmember.
14. The frame of any one of claims 1 to 13, wherein the middle portion comprises a rear left member extending upwardly from the left bottom distal end portion of the left bottom longitudinal member to the left distal end portion of the left top longitudinal member and a rear right member extending upwardly from the right bottom distal end portion of the right bottom longitudinal member to the right distal end portion of the right top longitudinal member.
15. The frame of any one of claims 1 to 14, wherein the engine compartment is adapted to receive a first engine having a first size or a second engine having a second size without modification of the left and right bottom longitudinal members and of the left and right top longitudinal members, the second size being larger than the first size.
16. The frame of claim 15, wherein the middle portion comprises a rear left engine mounting bracket, a front left engine mounting bracket, a rear right engine mounting bracket and a front right engine mounting bracket and wherein the rear and front left engine mounting brackets and the rear and front right engine mounting brackets comprise rear and front left connectors and rear and front right connectors for mounting one of the first and second engines to the middle portion.
17. The frame of any one of claims 1 to 16, wherein the front suspension comprises left and right front shock absorbers.
18. The frame of any one of claims 1 to 17, wherein the rear suspension comprises left and right rear shock absorbers.
19. A frame for an all-terrain vehicle, the frame comprising a main frame comprising a front portion, a middle portion and a rear portion extending along a longitudinal axis between a rear proximal end and a rear distal end, wherein the rear portion comprises: a left member adjacent the rear proximal end, the left member extending upwardly from a left bottom end portion to a left top end portion, and a right member adjacent the rear proximal end, the right member extending upwardly from a right bottom end portion to a right top end portion; a left transversal arm adjacent the rear proximal end, the left transversal arm extending transversely between a left proximal end portion and a left distal end portion, and a right transversal arm adjacent the rear proximal end, the right transversal arm extending transversely between a right proximal end portion and a right distal end portion, the left and right proximal end portions of the left and right transversal arms being pivotably mounted to the left and right bottom end portions of the left and right members; and a hitch receiver mounted to the left and right proximal end portions of the left and right transversal arms and to the left and right members, wherein the proximal end portions of the left and right transversal arms are sandwiched between the left and right members and the hitch receiver.
20. The frame of claim 19, wherein the proximal end portions of the left and right transversal arms are pivotably mounted rearwardly of the left and right bottom end portions of the left and right members.
21 . The frame of claims 19 or 20, wherein the hitch receiver comprises a central projection extending rearwardly along the longitudinal axis from a distal end portion to a proximal end portion, and left and right protrusions extending transversely from the distal end portion of the central projection, wherein the left and right protrusions of the hitch receiver are mounted to the left and right proximal end portions of the left and right transversal arms and to the left and right members.
22. The frame of claim 21 , wherein the left and right protrusions comprise left and right bottom protrusions extending transversely from the distal end portion, and left and right top protrusions extending transversely from the distal end portion, wherein the left and right bottom protrusions of the hitch receiver are mounted to the left and right proximal end portions of the left and right transversal arms, and wherein the left and right top protrusions of the hitch receiver are mounted to the left and right members.
23. The frame of claim 22, wherein the hitch receiver comprises a left flange between the left bottom and top protrusions and a right flange between the right bottom and top protrusions.
24. The frame of claims 22 or 23, wherein the hitch receiver comprises a left bottom flange between the left bottom protrusion and the central projection and a right bottom flange between the right bottom protrusion and the central projection.
25. The frame of any one of claims 22 to 24, wherein the central projection comprises exterior and inner walls and wherein the inner wall defines a housing for receiving an elongated portion of a hitch.
26. The frame of any one of claims 22 to 25, wherein the left and right members comprise left and right rear surfaces and wherein the left and right proximal end portions of the left and right transversal arms are mounted to the left and right rear surfaces.
27. The frame of claim 26, wherein the left and right proximal end portions of the left and right transversal arms comprise left and right rear surfaces, wherein the left and right bottom protrusions of the hitch receiver are mounted to the left and right rear surfaces of the left and right proximal end portions of the left and right transversal arms, and wherein the left and right top protrusions of the hitch receiver are mounted to the left and right rear surfaces of the left and right members.
28. The frame of any one of claims 22 to 27, wherein the left and right proximal end portions of the left and right transversal arms comprise left and right proximal ends extending longitudinally along left and right bottom mounting axes between the left and right bottom protrusions of the hitch receiver and the left and right members, the left and right proximal ends comprising left and right inner walls extending along the left and right bottom mounting axes and defining left and right housings.
29. The frame of claim 28, wherein the left and right bottom protrusions comprise left and right bottom apertures at respective distal ends and wherein the left and right top protrusions comprise left and right top apertures at respective distal ends, the left and right bottom apertures being around the left and right bottom mounting axes.
30. The frame of claim 29, wherein the left and right members comprise left and right top holes and left and right bottom holes, wherein the left and right top holes are aligned with the left and right top apertures, and wherein the left and right bottom holes are around the left and right bottom mounting axes.
31. The frame of claim 30, comprising left and right bottom fasteners mounted in the left and right bottom apertures, in the left and right housings and in the left and right bottom holes, and left and right top fasteners mounted in the left and right top apertures and in the left and right top holes for affixing the hitch receiver to the left and right members.
32. The frame of claim 31 , comprising left and right bushings mounted in the left and right housings and around the left and right bottom fasteners and wherein the left and right proximal ends are pivotably mounted around the left and right bushings and left and right bottom fasteners for allowing pivotable movement of the left and right transversal arms relative to the left and right bottom mounting axes.
33. The frame of claim 32, wherein the left and right members comprise left and right bottom projections extending forwardly along the left and right bottom mounting axes and wherein the left and right bottom projections comprise left and right inner walls defining left and right bottom channels aligned with the left and right bottom holes.
34. The frame of claim 33, wherein the left and right members comprise left and right top projections extending forwardly along left and right top mounting axes wherein the left and right top projections comprise left and right inner walls defining left and right top channels aligned with the left and right top holes.
35. The frame of claim 34, wherein the left and right bottom fasteners comprise left and right bottom bolts comprising left and right distal threaded ends and left and right bottom nuts, wherein the left and right top fasteners comprise left and right top bolts comprising left and right distal threaded ends and left and right top nuts, wherein the left and right distal threaded ends of the left and right bottom bolts extend forwardly outside the left and right bottom channels, wherein the left and right distal threaded ends of the left and right top bolts extend forwardly outside the left and right top channels, wherein the left and right bottom nuts are mounted to the left and right distal threaded ends of the left and right bottom bolts, and wherein the left and right top nuts are mounted to the left and right distal threaded ends of the left and right top bolts.
36. The frame of any one of claims 32 to 35, comprising a left shock absorber adjacent the rear proximal end, the left shock absorber extending upwardly from a left bottom end portion to a left top end portion, and a right shock absorber adjacent the rear proximal end, the right shock absorber extending upwardly from a right bottom end portion to a right top end portion, wherein the left and right bottom end portions of the left and right shock absorbers are mounted to the left and right transversal arms, and wherein upon pivotal movement of the left and right transversal arms, the left and right shock absorbers are compressed or expanded.
37. The frame of claim 36, wherein the left and right transversal arms are left and right bottom transversal arms, and wherein the rear portion of the frame comprises left and right top transversal arms adjacent the rear proximal end, wherein the left and right top transversal arms extend from left and right top proximal ends to left and right top distal ends, wherein the left and right top proximal ends of the left and right top arms are pivotably mounted to the left and right members, and wherein upon pivotal movement of the top and bottom left and right transversal arms, the left and right shock absorbers are compressed or expanded.
38. The frame of any one of claims 28 to 37, wherein the left proximal end of the left transversal arm comprises a left rear external circular wall facing the left bottom protrusion of the hitch receiver, wherein the right proximal end of the right transversal arm comprises a right rear external circular wall facing the right bottom protrusion of the hitch receiver, and wherein the left and right rear circular external walls and the left and right bottom protrusions define left and right rear spaces therebetween.
39. An all-terrain vehicle comprising a main frame comprising a front portion, a middle portion and a rear portion extending along a longitudinal axis between a rear proximal end and a rear distal end, wherein the middle portion is configured to receive an engine, and wherein the front portion comprises: a left bottom longitudinal member extending from a front left bottom proximal end portion to a front left bottom distal end portion; a right bottom longitudinal member extending from a front right bottom proximal end portion to a front right bottom distal end portion; a first bottom cross-member extending between the left and right bottom longitudinal members and comprising: left and right ends; a proximal and distal surfaces; a first left transversal member adjacent to the left bottom distal end portion, the first left transversal comprising a proximal end and a distal end; and a first right transversal member adjacent to the right bottom distal end portion, the first right transversal member comprising a proximal end and a distal end; wherein the proximal ends of the first left and right transverse members are pivotally connected to the bottom cross-member between the left and right longitudinal members.
40. The all-terrain vehicle of claim 39, wherein each of the first left and right transversal member comprises a front portion having a front distal end and a rear proximal end, and a rear portion having a rear distal end and a rear proximal end, wherein the rear proximal ends of rear portions of the first left and right transverse members are connected to the bottom cross-member between the left and right longitudinal members.
41 . The all-terrain vehicle of claims 39 or 40, wherein the first left transversal member is pivotably mounted on a left axe provided at the proximal surface of first bottom crossmember, and wherein the first right transversal member is pivotably mounted on a right axe provided at the proximal surface of the first bottom cross-member.
42. The all-terrain vehicle of any one of claims 39 to 41 , wherein the first left transversal member extends slightly upwardly and away from the bottom cross-member passing over the front left bottom longitudinal member and to a left a knuckle for mounting a left wheel; and wherein the first right transversal member extends slightly upwardly and away from the bottom cross-member passing over the front right bottom longitudinal member and to a right knuckle for mounting a right wheel.
43. The all-terrain vehicle of any one of claims 39 to 42 comprising a second bottom crossmember sandwiching the first left and right transversal members between the first bottom cross-member, wherein the second bottom cross-member securely fastens the first left and right transversal members, while allowing pivotal movement of the first left and right transversal members.
44. The all-terrain vehicle of claim 39 or 40, wherein the front portion comprises a left and right bottom fasteners mounted in first and second holes of the first bottom crossmember, wherein the left and right bottom fasteners comprise left and right bottom bolts comprising left and right distal threaded ends, the left and right mounting axes, and left and right bottom nuts, wherein the left and right distal threaded ends of the left and right bottom bolts extend forwardly through the first and second holes, and outside of the first cross-member, and wherein the second bottom cross-member is mounted on the left and right distal threaded ends.
45. The all-terrain vehicle of any one of claims 39 to 44, wherein the front portion comprises a left member extending upwardly from the left bottom distal end portion to a left top end portion; a right member extending upwardly from the right bottom distal end portion to a right top end portion; and a top cross-member extending between the left and right top ends.
46. The all-terrain vehicle of claim 45, wherein the front portion comprises a middle crossmember above the first bottom cross-member, and extending between the left and right members, wherein the middle cross-member comprises a mounting bracket for mounting a second left and right transversal members, wherein the second left transversal member is pivotably mounted to the mounting bracket and extends away from the middle cross-member passing over the front left bottom longitudinal member and to the left knuckle, and wherein the second right transversal member is pivotably mounted to the mounting bracket and extends away from the middle cross-member passing over the front right bottom longitudinal member and to the right knuckle.
47. The all-terrain vehicle of claim 46, wherein the front portion comprises left and right shock absorbers extending upwardly from their respective left and right second left and right transversal members to the top cross-member, wherein the left and right shock absorbers are pivotably mounted to the top cross-member, and wherein upon pivotal movement of the first and second left and right transversal members, and the left and right shock absorbers are compressed or expanded.
48. A rear suspension for an all-terrain vehicle including a main frame, the rear suspension comprising: a main swing arm including a left portion and a right portion, each of the left and right portions including a front end for pivotably mounting the main swing arm to the main frame of the all-terrain vehicle and a rear end, each of the left and right portions being configured to allow a torsional movement along a longitudinal axis of the left and right portions; a drive axle mounted to the rear end of the left and right portions; and at least one shock absorber having a first end mounted to the main swing arm and a second end mountable to the main frame of the all-terrain vehicle.
49. The rear suspension of claim 48, wherein the main frame of the vehicle comprises left and right brackets, and wherein the front ends of the left and right portions of the main swing arm are respectively pivotably mounted to the left and right brackets.
50. The rear suspension of claims 48 or 49, wherein the at least one shock absorber comprises a left shock absorber and a right shock absorber.
51. The rear suspension of claim 50, wherein the first end of the left shock absorber is mounted proximal to the rear end of the left portion of the main swing arm and the first end of the right shock absorber is mounted proximal to rear end of the right portion of the main swing arm.
52. The rear suspension of any one of claims 1 to 51 , further comprising a differential operatively coupled to the drive axle.
53. The rear suspension of any one of claims 1 to 52, wherein each of the left and right portions of the main swing arm comprises: a front portion extending from the font end of to an intermediate location; rear portion extending from the intermediate location to the rear end.
54. The rear suspension of claim 53, wherein the rear portion is generally T-shaped.
55. The rear suspension of claim 54, wherein the drive axle comprises a sleeve portion, and wherein rear end of the rear portion is attached to the sleeve portion.
56. The rear suspension of claim 55, wherein the rear end of the rear portion is welded to the sleeve portion.
57. The rear suspension of claim 56, wherein the drive axle further comprises a shaft member rotatably received in the sleeve portion.
58. The rear suspension of any one of claims 53 to 57, wherein the front portion comprises a generally cylindrical tube extending from the front end to the intermediate location.
59. The rear suspension of any one of claims 53 to 58, wherein the front end of the front portion comprises a recess extending transverse to the longitudinal axis of the cylindrical tube, the recess being configured for receiving a bushing therein for securing the front portion to a corresponding bracket of the lower left tube of the main frame.
60. The rear suspension of claim 59, wherein the bushing allows the corresponding left or right portion to pivot about a pivot axis P-P and a torsion movement about an axis LT- LT of the corresponding left or right portion relative to the bracket to which it is attached without compromising the pivoting movement about axis P-P.
61 . The rear suspension of claim 53, wherein the front and rear portions are two discrete components attached to one another.
62. The rear suspension of claim 61 , wherein the front and rear portions are attached to one another by welding.
63. The rear suspension of claim 61 , wherein the front and rear portions are attached to one another using nuts, bolts, brackets or collars.
64. The rear suspension of claim 53, wherein the front and rear portions of the left portion are manufactured as a single piece.
65. The rear suspension of any one of claims 53 to 64, wherein the rear portion has a generally oblong cross-section.
66. The rear suspension of any one of claims 53 to 65, wherein the rear portion is sized, shaped and made of a material allowing a limited torsion of the rear portion about a longitudinal axis LT-LT.
67. The rear suspension of any one of claims 53 to 66, wherein at least one of the front portion and rear portion is made of Strenx™ 700 structural steel.
68. The rear suspension of claim 67, wherein the Strenx™ 700 structural steel has a thickness of about 0.0551 inch (1 .4 mm).
69. An all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steerthe front wheels of the all-terrain vehicle, the all-terrain vehicle comprising: a front end; a rear end; a service center compartment for providing a user with an access to at least one component of the all-terrain vehicle for maintenance thereof; and a service center cover for removably closing said service center compartment, the service center comprising an air entry into an airbox; wherein the service center cover is located in front of the steering device.
70. The all-terrain vehicle of claim 69, wherein the steering device comprises a handlebar.
71 . The all-terrain vehicle of claims 69 or 70, wherein the at least one component of the all-terrain vehicle is selected from a group comprising a portion of an airbox, a coolant bottle, a fuse box and a CVT air entry.
72. The all-terrain vehicle of any one of claims 69 to 71 , wherein the service center cover is configured for easy removal.
73. The all-terrain vehicle of claim 72, wherein the service center cover is removably securable to the service center compartment.
74. The all-terrain vehicle of claim 73, wherein the service center cover is removably securable to the service center compartment using at least one of a toolless % turn, a toe-in, a snap engagement means, a hoop and loop fastener or a magnet.
75. The all-terrain vehicle of any one of claims 69 to 74, wherein the service center cover comprises at least one electrical component.
76. The all-terrain vehicle of claim 75, wherein the at least one electrical component is selected from a group comprising a display for displaying information concerning systems of the all-terrain vehicle, a communication device to the driver and an electric outlet.
77. The all-terrain vehicle of claims 75 or 76, wherein the all-terrain vehicle further comprises at least one wire extending from service center compartment and connectable to the service center cover for supplying the at least one electrical component with electric power or data.
78. The all-terrain vehicle of claim 77, wherein the at least one wire comprises such a length as to allow the service center cover to be removed from the service center compartment and placed to one side thereof to allow access the at least one component within the service center compartment without having to disconnect the at least one wire.
79. The all-terrain vehicle of claim 77, wherein the at least one wire is detachably connectable to at least one of the service center compartment and the service center cover.
80. The all-terrain vehicle of any one of claims 71 to 79, wherein the airbox comprises an airbox body provided with an airbox opening and defining an airbox compartment, an airbox cover removably mounted to the airbox body for closing the airbox opening, an air inlet allowing air to enter the airbox body, an air outlet for allowing air to exit the airbox housing to reach an engine of the all-terrain vehicle and an air filter removably received into the airbox body through the airbox opening for filtering the air between the air inlet and the air outlet, wherein the airbox opening and the airbox cover are located in the service center compartment and allow for the air filter to be removed or installed via access to the service center compartment.
81 . An all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steerthe front wheels of the all-terrain vehicle, the all-terrain vehicle comprising: a front end; a rear end; an airbox comprising an airbox body provided with an airbox opening and defining an airbox compartment; an airbox cover removably mounted to the airbox body for closing the airbox opening, an air inlet allowing air to enter the airbox body; an air outlet for allowing air to exit the airbox housing to reach an engine of the all-terrain vehicle; and an air filter removably received into the airbox body through the airbox opening for filtering the air between the air inlet and the air outlet, wherein the airbox opening and the airbox cover are in front of the steering device.
82. The all-terrain vehicle of claim 81 , wherein the steering device comprises a handlebar.
83. The all-terrain vehicle of claims 81 or 82, wherein the all-terrain vehicle further comprises: a service center compartment for providing a user with an access to at least one component of the all-terrain vehicle for maintenance thereof; and a service center cover for removably closing said service center compartment, wherein the service center cover is located in front of the steering device, wherein the airbox opening and the airbox cover located in the service center compartment are accessible to a user when the service center cover is removed.
84. The all-terrain vehicle according to any one of claims 81 to 83, wherein the airbox body comprises a top portion and a bottom portion, the top portion being configured to receive the air inlet.
85. The all-terrain vehicle according to claim 84, wherein the top portion further comprises the airbox opening.
86. The all-terrain vehicle according to any one of claims 81 to 85, wherein the airbox cover is configured to abut the airbox opening and to be removably secured to the airbox body.
87. The all-terrain vehicle of claim 86, wherein the airbox cover is secured to the airbox body and held in place using securing devices configured to be manipulated and removed without the use of tools.
88. The all-terrain vehicle of claim 87, wherein the securing devices comprise one or more over-center clips.
89. The all-terrain vehicle of any one of claims 81 to 88, wherein the airbox cover comprises at least one protrusion extending into the airbox body when the airbox cover is secured to the airbox body, the at least one protrusion holding the air filter in an installed position.
90. The all-terrain vehicle of claim 89, wherein the at least one protrusion extends substantially vertically.
91 . The all-terrain vehicle of claims 89 or 90, wherein the at least one protrusion comprises at least one of a notch, a recess or an indentation for receiving therein a portion of the air filter to hold the air filter in the installed position.
92. The all-terrain vehicle of any one of claims 81 to 91 , wherein the airbox further comprises a Helmholtz resonator received in the airbox body.
93. An all-terrain vehicle comprising a frame mounted on a pair of front wheels and a pair of rear wheels and a steering device operatively coupled to the front wheels for allowing a user to steerthe front wheels of the all-terrain vehicle, the all-terrain vehicle comprising: front end; a rear end; a radiator mounted in front of the steering device and above the front wheels; a radiator cover for substantially covering the radiator, the radiator cover comprising: a pair of spaced-apart side covers extending generally vertically on each side of the radiator; a top cover extending between the spaced apart side covers and generally parallel to the radiator, the top cover being pivotably attached to one of the radiator and the spaced-apart side covers; an air opening defined on a front end of the radiator cover, wherein the spaced-apart side covers and the top cover of the radiator cover contribute to generate a ram air effect of the air entering the air opening inside the radiator cover for ramming oncoming air onto the radiator during operation of the all- terrain vehicle.
94. The all-terrain vehicle of claim 93, wherein the radiator extends at a rearward angle between the front end of the all-terrain vehicle and the rear end thereof.
95. The all-terrain vehicle of claim 94, wherein the rearward angle of the radiator varies between 30 and 60 degrees relative to a horizontal plane.
96. The all-terrain vehicle of any one of claims 93 to 95, wherein the spaced-apart side covers extend substantially vertically along a longitudinal axis of the all-terrain vehicle.
97. The all-terrain vehicle of claim 96, wherein the all-terrain vehicle further comprises a pair of wheel fenders for covering the front wheels of the all-terrain vehicle, wherein each of the spaced-apart sides covers extend vertically from a corresponding wheel fender.
98. The all-terrain vehicle of claim 93, wherein the top cover comprises a front end and a rear end, wherein the front end of the top cover is pivotably attached to the spaced- apart side covers.
99. The all-terrain vehicle of claim 98, wherein the radiator cover further comprises at least one latching device for securing the top cover to the spaced-apart side covers and maintain the top cover in a closed position.
100. The all-terrain vehicle of any one of claims 93 to 99, wherein the radiator further comprises a removable toolkit.
101. The all-terrain vehicle of claim 100, wherein the removable toolkit is removably securable to an inner face of the top cover.
EP24756450.3A 2023-02-17 2024-02-16 Frame for an all-terrain vehicle and all-terrain vehicle comprising the same Pending EP4665633A1 (en)

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US202363446420P 2023-02-17 2023-02-17
PCT/IB2024/051494 WO2024171134A1 (en) 2023-02-17 2024-02-16 Frame for an all-terrain vehicle and all-terrain vehicle comprising the same

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