An ATV is disclosed having a frame and a plurality of wheels. A power train is defined by an engine, transmission and front and rear final drives. The engine is mounted to the frame skid plate by way of die cast legs. The transmission may include a CVT, which includes a cooling system to cool the interior of the CVT. The cooling system include a fan positioned on the driven clutch causing a reverse suction air flow, back through the drive clutch, with the air exhausting at the front of the engine.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to an ALL TERRAIN VEHICLE (ATV) and, more particularly, to an ATV having improved ergonomics and performance.

Generally, all terrain vehicles (ATVs) are used to carry one or two passengers and a small amount of cargo over a variety of terrains. Due to increasing recreational interest in ATVs, specialty ATVs, such as those used for trail riding, racing, and cargo hauling have entered the market place. Most ATVs include an engine including between one and three cylinders. Most ATVs include a straddle or saddle type seat positioned above the engine. Depending on the engine size and the number of cylinders, the width of the engine may become substantial, thereby requiring a wider seat. A wider seating surface may become uncomfortable for the rider, particularly shorter riders who may have trouble reaching the floorboards.

According to an illustrative embodiment of the present disclosure, an all-terrain vehicle includes a frame having longitudinally spaced-apart ends defining a first longitudinal axis. A pair of front wheels and a pair of rear wheels are operably coupled to the frame. An engine is supported by the frame and includes a plurality of cylinders and a crankshaft driven by the plurality of cylinders.

SUMMARY OF THE DISCLOSURE

In one aspect, an all terrain vehicle comprises a frame, comprising a lower longitudinally extending frame portion and an upper frame portion. The upper frame portion has longitudinally extending upper frame rails, at least one of the upper frame rails having an inward transition defining a first distance between the upper frame rails forward of the inward transition, and a second distance rearward of the inward transition, where the first distance is greater than the second distance. An engine is supported by the lower longitudinally extending frame portion, the engine having a crankshaft and a single cylinder, the crankshaft being oriented horizontally and transverse to a longitudinal axis of the vehicle, the cylinder being tilted forward with an exhaust port extending generally forwardly and an intake port extending generally rearwardly. An air box is supported by the upper frame rails, rearward of the inward transition. A throttle is positioned intermediate and coupled between the airbox and engine. Ground engaging members are drivingly coupled to the engine.

In another aspect, an all terrain vehicle comprises a frame; an engine supported by frame, the engine having a crankshaft being oriented transverse and horizontal to a longitudinal axis of the vehicle, the engine having a crankshaft and a single cylinder, the cylinder having an exhaust port extending generally forwardly and an intake port extending generally rearwardly. A continuously variable transmission (CVT) is positioned rearward of the engine and has a driven shaft being oriented transverse and horizontal to a longitudinal axis of the vehicle, the CVT further comprising a drive clutch coupled to the crankshaft and a driven clutch coupled to the driven shaft. A cooling assembly is coupled to the CVT, having a cover enclosing the drive and driven clutches, an intake duct is coupled to the cover to supply air to the driven clutch, and an exhaust dust is coupled to the cover to exhaust air from the driven clutch, the exhaust duct having an outlet port exhausting air generally adjacent to the engine exhaust manifold. Ground engaging members are drivingly coupled to, the engine.

In yet another embodiment, an all terrain vehicle comprises a frame, comprising a lower longitudinally extending frame portion and an upper frame portion, and a generally vertically extending support positioned between the upper and lower frame portions. An engine has a wet sump oil supply, the engine being coupled to the frame forward of the generally vertically extending support. Engine supports are coupled to the lower longitudinally extending frame portion and the engine, and suspend the engine above the lower longitudinally extending frame portion, and a rear engine mount couples the engine to the generally vertically extending support. Ground engaging members are drivingly coupled to, the engine.

In another aspect of the disclosure an all terrain vehicle comprises a frame, comprising a lower longitudinally extending frame portion and an upper frame portion, and a generally vertically extending support positioned between the upper and lower frame portions. The ATV includes an engine and a transmission where the rear side of the engine is coupled to a front side of the generally vertically extending support and a front side of the transmission is coupled to a rear side of the generally vertically extending support. Ground engaging members are drivingly coupled to the engine.

In another aspect, an all terrain vehicle comprises a frame, comprising a lower longitudinally extending frame portion and an upper frame portion. A powertrain is defined by an engine; a drive assembly, including a transmission, and a front final drive and a rear final drive. Engine supports are coupled to the lower longitudinally extending frame portion and the engine, and suspend the engine above the lower longitudinally extending frame portion. The rear final drive is coupled to rear wheels and the front final drive is coupled to the front wheels by a drive shaft, the drive shaft extending from the drive assembly to the front final drive, with the engine supports straddling the drive shaft.

In another aspect, an all terrain vehicle comprises a frame having a lower longitudinally extending frame portion and an upper longitudinally extending frame portion. The upper frame portion has longitudinally extending upper frame rails, where at least one of the upper frame rails has an inward transition defining a first distance (D1) between the upper frame rails forward of the inward transition, and a second distance (D2) rearward of the inward transition, where the first distance is greater than the second distance. The exhaust system comprises an exhaust tube with an inwardly angled portion at the inward transition, with the exhaust tube extending generally rearwardly along the upper frame rail portion rearward of the inward transition.

In another embodiment, an all terrain vehicle comprises an engine and a frame having a lower longitudinally extending frame portion and an upper longitudinally extending frame portion. An exhaust system comprises an exhaust tube extending generally rearwardly along the frame rearward of the engine and an exhaust shield, surrounding at least a portion of the exhaust tube, the shield including an inner and outer shield which conform to encompass a portion of the length of the exhaust tube, the inner and outer shields being coupled to the frame.

DETAILED DESCRIPTION OF THE DRAWINGS

Corresponding reference characters indicate corresponding parts throughout the several views. Unless stated otherwise the drawings are proportional. The embodiments disclosed below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. While the present disclosure is primarily directed to a utility vehicle, it should be understood that the features disclosed herein may have application to other types of vehicles such as all-terrain vehicles, motorcycles, watercraft, snowmobiles, people movers, and golf carts.

With reference first toFIGS. 1 and 2, a vehicle2is shown as an all-terrain-vehicle (ATV) including a frame4coupled to and supported by front wheels6and rear wheels8. Front wheels6comprise tires6aand rims6b. Rear wheels8comprise tires8aand rims8b. ATV generally includes a power train shown at10, which will be described in further detail herein. Front wheels6are coupled to frame4by way of a front suspension12, and rear wheels8are coupled to frame4by way of a rear suspension14. ATV further includes a seat assembly16, which as shown inFIGS. 1 and 2is for a single rider, but ATV2could be modified to incorporate two riders as described herein. ATV2also includes a steering assembly20for steering at least the front wheels6as is known in the art.

ATV2also includes an outer body, generally formed of a plastic material. Outer body may include at least foot pedestals18for placement of a rider's feet while riding. A front rack22is provided forward of steering assembly20and a rear rack24is provided rearward of seat16. It should be appreciated that front rack22could include a plurality of tie downs and/or could include a moveable portion such as a hood to expose a storage cavity for storing items while riding. It should also be appreciated that rear rack24could include integrated tie down portions30such as those described in U.S. Ser. No. 12/012,587 filed Feb. 4, 2008, the subject matter of which is incorporated herein by reference. Front and or rear rack could also include apertures32for receiving an expansion member similar to that shown and/or described in U.S. Pat. No. 8,267,034, the subject matter of which is incorporated herein by reference.

With reference now toFIGS. 3-6, frame4will be described in greater detail. As shown inFIGS. 3-6, frame4includes a lower frame portion40, upper frame portion42, front frame portion44, and removable frame portion46(FIG. 6). Lower frame portion40includes a longitudinally extending rail50coupled to longitudinally extending rail52. Rail50includes a front portion50a, transition portion50b, center section50c, transition section50d, and rear portion50e. Similarly, and with reference toFIG. 4, rail52includes front portion52a, transition portion52b, center portion52c, transition portion52d, and rear portion52e. As shown, front suspension brackets56(FIG. 3) are coupled to rail portion50aand front suspension brackets58(FIG. 4) are coupled to front rail portion52a. Skid plates60,62, and64are coupled to and span longitudinally extending rails50and52. Engine mount plate66(FIG. 4) also spans and is coupled to longitudinally extending rails50,52. A plurality of channels such as68and70(FIG. 4) may also couple longitudinally extending rails50,52. A left foot rest support72(FIG. 3) is coupled to rail50, and a right foot support74(FIG. 4) is coupled to rail52. As shown inFIG. 3, a left rear suspension bracket78includes mounting brackets80, while a right rear suspension bracket82(FIG. 4) includes mounting brackets84.

With reference still toFIG. 3, upper frame portion42includes a left longitudinally extending rail100and a right longitudinally extending rail102. As best shown inFIG. 5, left longitudinally extending rail100includes a front portion100ahaving a transition section at100b, which leads into rear portion100c. Right longitudinally extending rail102includes a forward portion102a, having a transition section102bleading into rear portion102c. As shown best inFIG. 3, front bracket106extends upwardly from, and couples together, rails100,102. Rail100includes an intermediate bracket108and rail102includes an intermediate bracket110. A rear shock mount112is coupled to and spans rear rail portions100c,102c, and includes a mounting bracket114. A pair of brackets116,118is also coupled to longitudinally extending rails100,102, for mounting rear rack24. Frame4includes upright rails120coupling lower (40) and upper (42) frame portions together as best shown inFIG. 4. Frame4further includes a vertically extending support member122spanning between lower rails50,52and upper rails100,102as further described herein.

With reference now toFIG. 6, front frame portion44includes vertical uprights123, which support a shock tower124and support plate126. Front frame portion44further includes radiator mount brackets130including an upper support plate132and downwardly extending support legs134. Support plates132are coupled to vertical uprights123and legs134are coupled to upwardly projecting portions50f,52fof rails50,52, respectively, as best shown inFIG. 7. Front frame portion44further includes lower support plate140coupled between rails50,52, which includes a front mounting bracket142having mounting apertures142a,142b.

With reference still toFIG. 6, removable portion46includes vertical uprights150having an upper end150acoupled to cross-bracket152, and lower ends150bcoupled to cross-bracket154. A central cross-bracket156also couples upright members150. Cross-bracket152includes rearwardly extending bracket arms160having plate portions160awith apertures160b, which couple with forward ends100d,102dof upper rails100,102, by way of fasteners164,166. Lower cross bracket154includes a lower plate portion170having an embossment at172including openings174. Embossment172fits against mounting bracket142and fasteners176are receivable through opening174and are threadably received in threaded apertures142a.

With reference now toFIGS. 7-11, power train10is shown as coupled to frame4. As shown, power train10is comprised of an engine200, a rear drive assembly202, which includes transmission204and rear final drive206. Power train10further includes a front final drive208coupled to rear drive assembly202by way of drive shaft210, as described further herein. Engine could include various aspects of the engines shown in U.S. patent application Ser. No. 12/928,498 filed Dec. 13, 2010, and Ser. No. 13/242,229 filed Sep. 23, 2011, the subject of which is incorporated herein by reference. As shown inFIG. 7, power train10does not show the continuously variable transmission (CVT), which couples together engine output shaft212and input shaft214of transmission204as described herein in greater detail. It should be understood that engine output shaft212is the drive end of a crankshaft, where the crankshaft is oriented horizontally and transverse to a longitudinal axis of the vehicle.

With respect now toFIGS. 7-11, the mounting of engine200to frame4will be described in greater detail. As shown inFIG. 9, engine200is coupled to engine mount plate66by way of front bracket assembly220and rear bracket assembly222. As shown inFIG. 10, front bracket assembly220includes upstanding support legs or brackets224, which may be die cast, having a lower mounting surface at226and an upper flange228having mounting apertures228a. An isolation mount230is provided having an integrated threaded insert232having a male threaded end at232aand a female threaded end at232b. Engine mount plate66includes angled plate surfaces66ahaving apertures66b, which receive threaded portion232atherethrough, which can be coupled by way of fastener234. It should be appreciated that isolation mount230further includes a resilient grommet portion236, which is positioned against plate portion66a. As shown inFIG. 10, engine200includes integral flanges240, which are profiled to conform with flanges228of bracket224whereby fasteners244may be received through apertures228aand through flanges240, to receive fasteners246retaining engine to bracket224. It should also be appreciated that bracket224may be placed upon isolation mount230and fastener250may be received through aperture226aof bracket224and into threaded insert portion232bof isolation mount230. Brackets224and engine200are shown in their coupled state inFIG. 9.

With reference still toFIG. 10, rear bracket assembly222generally includes bracket260, fasteners262,264; fasteners266; bracket270; sleeve271; isolation bushings272; and fasteners274,276. As best shown inFIG. 10A, bracket260includes a front plate portion260aand upper and lower plate portions260b. Plate portions260binclude apertures260cand plate portion260aincludes apertures260d. Bracket270includes a cylindrical portion270ahaving an internal diameter at270b. Two integral bosses270cextend transversely of cylindrical portion270aand include apertures at270d. Bushings272include an outer diameter portion272aprofiled to be received within diameter portion270band an outer annular portion272bhaving an inner face272c. Bushings272further include openings at272dprofiled to receive sleeve271.

With reference now toFIGS. 10A and 11, vertically extending member122generally includes a front wall122aand sidewalls122b,122c. Front wall portion122aincludes an upper window at122dand a lower window at122e. Sidewall122cincludes bracket280having upper and lower walls280a, and an inwardly facing wall280bhaving an aperture at280c. As shown inFIG. 11, sidewall122cfurther includes upper and lower apertures282and central aperture284coaxially aligned with aperture280c(FIG. 10A). With reference again toFIG. 11, side wall122bincludes bracket member286having upper and lower wall286aand an inner wall at286b. Inner wall286bincludes upper and lower apertures288and a central aperture290(through which fastener274extends). Side wall122bincludes upper and lower apertures292coaxially aligned with apertures288and a central opening294coaxially aligned with aperture290. Thus the attachment of engine200to frame4by way of bracket assembly222will now be described.

As shown inFIGS. 10 and 10A, bracket260is coupled to bosses300(FIG. 10) on a rear side of engine200and is coupled in place by fasteners266projecting through apertures260d(FIG. 10A). Resilient bushings272are positioned in cylindrical portion270awith sleeve271positioned through openings272dof bushings272. This assembly is positioned through window122dof vertical extending support member122and fastener274(FIG. 10) may be positioned through opening294into aperture290(FIG. 11) and through sleeve271. A threaded end274a(FIG. 11) of fastener274projects through aperture280cof bracket280(FIG. 11) and fastener276couples with threaded end274aof fastener274. As should be appreciated, apertures294and284may be used for socket wrenches, which engage fasteners274,276to draw the two fasteners together. Fasteners262and264, maintain brackets260,270together extending through apertures260cand270d(FIG. 10A).

With reference still toFIG. 11, vertically extending support member122further includes on a right side thereof, an indentation or notch300, which provides clearance for an exhaust system, as further described herein. Vertically extending support member122also includes an access opening302for an engine mounting bolt.

With reference now toFIG. 12, the above-described frame4and vertically-extending support member122, also accommodates an alternate engine310having front bracket assembly320and rear bracket assembly322. Assembly320includes bracket324having an upper flange328for mounting to a front of engine310and resilient bushings330substantially similar to bushings230as described above. Rear bracket assembly322includes a cylindrical portion370having resilient bushings372and fastener374, which operate in a substantially similar way as described above with reference to rear bracket assembly222. Front bracket assembly320and rear bracket assembly322mount to frame in an identical manner as that described above, that is to engine mount plate66, and to vertically-extending support member122.

With reference now toFIG. 13, engine200is shown with oil pan380removed. It should be appreciated that engine200is a wet sump type engine, meaning that the oil supply is retained within oil pan380. Snorkel382generally extends downwardly into the pan380to accommodate the tipped forward aspect of the engine orientation.

With reference now toFIGS. 14 and 15, the coupling of rear drive assembly202to frame4will be described in greater detail. As shown, rear drive assembly202includes input shaft214(FIG. 7) and has rear output400at rear final drive206and a front drive assembly402(FIG. 14) having a front drive shaft404. As shown, transmission204includes a front integrated bracket410(FIG. 15), having transverse bosses410aand apertures410b. A U-shaped cutout410cis provided which extends rearwardly as described herein. Rear final drive206includes a rear bracket412, having a transverse boss412awith aperture412b. Boss414is also provided, having an aperture at414a. As shown best inFIG. 15, rear bracket78includes upstanding bracket arms78aand78b, having mounting apertures at78cand78drespectively. Rear final drive206also includes an upper transversely extending boss420, having aperture420a. A bracket422is provided, having a front plate portion422a, side plates422b, mounting apertures422cand422d.

Thus, mounting rear drive assembly202first includes coupling bracket422to rear final drive206by attaching bracket422to transverse boss420. It should be appreciated that a fastener426may be positioned through apertures422dof bracket422and through aperture420aof boss420. A counter fastener428couples with fastener426to affix bracket422to final drive206. Rear drive assembly202is now coupled to the lower and upper frame portions40,42, as described herein. As shown inFIG. 15, rear final drive202is positioned with bracket422adjacent to cross-member112; rear final drive206adjacent to rear bracket78; and with a front of transmission204adjacent to vertically-extending support member122. Apertures422cof bracket422are now aligned with apertures112aand fasteners430,432, may be applied to couple rear final drive206to upper frame portion42. Apertures412band414aof final drive206are also positioned adjacent to apertures78cand78dof bracket78, respectively and the fasteners438,440may be utilized to couple rear final drive206to rear bracket78. Finally, bosses410of transmission204are positioned between bracket286and side wall122cof vertically-extending support member122. More particularly, apertures410bare aligned with apertures288and282and fasteners442extend through apertures288,292and282, and couple with fasteners444to retain front bracket410of transmission204to vertically-extending support member122.

It should be appreciated that bracket410, when coupled to bracket286, is coupled to the same bracket as rear bracket assembly222for engine200(seeFIG. 11). Furthermore, cut-out410cis profiled to overlap cylindrical portion270of rear bracket assembly222. As mounted, front drive assembly402is positioned laterally outside of vertically-extending support member122and in particular, side plate122cwith drive shaft404spanning side plate122c.FIG. 14also shows drive shaft404coupling with front drive shaft210and front drive shaft210extends inside of engine bracket224(FIG. 8), such that bracket224straddles drive shaft210. Furthermore, window122eallows airflow from a front side of the vertically extending support member122, through to a rear side of the vertically extending support member122, cooling engine200and allowing removal of heat from the operator's area.

With reference now toFIGS. 16-20, an exhaust system450of the ATV2will be described. As best shown inFIG. 16, exhaust system450generally includes an exhaust manifold452, exhaust tube454, front shield456, rear shield458, and muffler460. With reference now toFIG. 17, exhaust manifold452includes a first end460receivable within an exhaust port of engine200and a flange462for direct connection with engine200. Exhaust manifold452also includes a bend at464and a coupling end at466. As shown inFIG. 19, exhaust tube454includes a coupling470which couples with coupling466of manifold452which transitions into bend portion472. Exhaust tube section474transitions from portion472and inclines upwardly and inwardly, towards a longitudinal centerline of frame4. Portion476transitions from portion474and extends generally horizontally but continues transitioning inwardly towards frame4longitudinal center line. Portion478extends generally longitudinally and horizontally rearwardly to portion480which inclines outwardly away from longitudinal centerline of frame4and upwardly to transition section482and into muffler460. With reference toFIGS. 17 and 19, exhaust tube472includes first and second brackets490,492, for mounting shield456as described herein. Exhaust tube454also includes bracket494coupled to portion478for coupling to frame4as described herein. Furthermore, muffler460includes brackets496and498.

Frame4includes brackets for coupling of exhaust system450thereto. With reference toFIG. 19, vertically extending support member122includes a bracket500coupled to sidewall122chaving a slot at502. Bracket494includes aperture494awhich can be positioned adjacent to slot502. A plurality of fasteners (FIG. 19) retain flange494and exhaust tube454to bracket500and to frame4.

With reference still toFIG. 19, bracket510is coupled to rail portion102cby way of fasteners, and bracket510includes an angled plate portion510ahaving a mounting aperture at510b. Each of brackets496and498include mounting slots such as496aand thus bracket496may be positioned adjacent to flange116aand bracket498may be positioned adjacent to flange510aand a plurality of fasteners may couple the muffler460to frame4.

Thus as shown inFIG. 20, ATV2has a frame4having lower longitudinally extending frame portion40and an upper longitudinally extending frame portion42. The upper frame portion has longitudinally extending upper frame rails100,102, where at least one of the upper frame rails, in this case102, has an inward transition102bdefining a first distance (D1) between the upper frame rails100c,102aforward of the inward transition, and a second distance (D2) rearward of the inward transition, where the first distance is greater than the second distance. The exhaust system comprises an exhaust tube454with an inwardly angled portion476at the inward transition102b, with the exhaust tube454extending generally rearwardly at478along the upper frame rail portion102crearward of the inward transition102b.

With reference now toFIG. 17, front shield456generally includes a front portion520, a central portion522, and a rear portion524. Front portion520includes an outer wall520aand angled walls520band520c. Angled walls520band520ctransition into generally parallel walls520dand520e, respectively. Furthermore, walls520dand520etransition into walls520fand520grespectively. As shown, angled walls520band520cflare outwardly while walls520fand520gare angled in the same direction. Each of walls520dand520einclude an aperture at526which correspond with brackets490,492, such that fasteners may couple shield456to exhaust tube454. Shield456is shown in a mounted position inFIG. 16.

With reference now toFIG. 18, rear shield458will be described in greater detail. As shown, shield458is comprised of a two piece shield including shield portion458aand shield portion458b. As shown, shield portion458aincludes a generally vertically extending plate550having a lower tab at552having an aperture at554. Plate portion550extends rearwardly to form a transition portion at556to conform to exhaust tube454. Shield portion458afurther includes a radius portion558transitioning into an upper wall portion at560. Upper wall portion560includes mounting apertures at562. As also shown inFIG. 18, shield portion458bincludes a plate portion570having a rear transition portion572conforming to exhaust tube454and upper tab portion574is reversely bent and includes mounting apertures576which correspond to mounting apertures562. In this manner, shield portions458aand458bare positioned in a surrounding relation to exhaust tube454with upper wall portion560overlapping upper portion574with fasteners580projecting through apertures562,576, and into threaded engagement with threaded apertures578of rail portion100c. A fastener582may also be positioned through aperture554and into threaded engagement with aperture504aof tab504.

The fully installed exhaust system450is shown inFIG. 16with shield456coupled to exhaust tube454. Shield portions458aand458bare also shown coupled to frame4in a totally overlapping relationship with exhaust tube454. The two piece arrangement of the shield458allows for a complete enclosure of the exhaust tube without a bend radius which could damage the formation of the shields. As installed, exhaust tube454tucks into notch300of vertically extending support122. As shown best inFIG. 20, exhaust tube454conforms tightly to upper frame portion42. More particularly, transition portion474of exhaust tube454raises exhaust tube portion476to be positioned adjacent to rail portion102b, where it conforms closely to portion102b, and exhaust tube portion478conforms closely to rail portion102c. This provides a narrow overall vehicle for the rider to straddle.

With reference now toFIGS. 21-26, CVT600will be described in greater detail. The location of CVT600is shown inFIG. 1on the left hand side of ATV2, and as should be appreciated, couples together engine output shaft212and transmission input shaft214(FIG. 7). With reference first toFIGS. 21 and 22, CVT600includes a drive clutch602, driven clutch604, outer cover606, intake duct608, and exhaust duct610. With reference now toFIGS. 23 and 24, CVT600is shown in an exploded manner. As shown, CVT600further includes internal annular ring612and rear plate614. The individual components of the CVT600will now be described in greater detail.

As shown inFIGS. 23 and 24, CVT cover606includes two components portion606aand606b. CVT cover portion606aincludes a central cover portion620and an enlarged cover portion622, which overlaps drive clutch602. Central cover portion620includes an intake duct at630while enlarged housing portion622includes an exhaust duct632. As shown best inFIG. 24, enlarged housing portion622includes a cylindrically shaped volume640profiled to receive drive clutch602and has an annular wall at642providing an opening at644communicating with duct632.

Housing portion620includes an outer wall at650having an opening which communicates with intake duct630. Wall652of housing portion620includes standoffs at654profiled to mount annular ring612. Annular ring612is generally shaped to conform to an inner volume defined by walls650and652. Annular ring612includes mounting apertures660located to correspond with standoffs654whereby fasteners664may be received through apertures660and threadably received in standoffs654to retain annular ring612within housing606a. Annular ring612includes an end wall portion662which extends towards and seats against wall652(FIG. 25). Annular ring612further includes a circular opening at668as shown in bothFIGS. 24 and 25as described further herein. CVT cover portion606aalso includes an annular lip at670with mounting bosses672surrounding the lip as shown best inFIG. 24.

With reference still toFIG. 24, housing portion606bincludes an annular lip680including a channel682(FIGS. 23 and 25) with a seal684positioned in channel682. Cover portion606bincludes threaded bosses at690which correspond with bosses672such that fasteners694may be received through bosses672into threaded apertures of bosses690to enclose the two cover halves as shown inFIG. 25.

With reference now toFIGS. 23-25, drive clutch602will be described. As shown, drive clutch602includes a clutch sheave700defined by clutch halves702,704. Centrifugal weights706are provided as is known in the art. Impeller blades710(FIGS. 24, 25) are defined on clutch half702to exhaust air as defined herein. Clutch602further includes shaft714having tapered opening716which receives a fastener such as718to couple clutch602to engine output shaft212(FIG. 7).

With reference still toFIGS. 23-25, driven clutch604will be described in greater detail. Driven clutch604is defined by clutch halves730and732and which together define a sheave740. Clutch halves730,732are moveable on a shaft742which includes an opening744to couple with transmission input shaft214(FIG. 7) by way of fastener750. Driven clutch604includes a bull nose portion760which protrudes through the opening668positioning impeller blades762proximate to opening668and to intake duct630as described herein.

Finally, and with reference toFIG. 24, intake duct608includes main duct portion770having an intake port at772and an exhaust port at774which couples to intake duct630by way of clamp776. Intake duct608further includes an intake snorkel at780having an intake at782and an exhaust at784. Exhaust784is coupled to intake port772by way of transition piece790. As also shown inFIG. 24, exhaust duct610includes an intake port at800coupled to exhaust port632by way of clamp802. Exhaust duct610includes a radius portion at804with a generally vertically extending section at806with a reverse bend at808and an exhaust port at810. As shown, exhaust port810projects generally vertically downwardly and creates a rectangular notch812within the outer envelope of duct610as described herein.

With reference now toFIG. 25, the operation of CVT600will be described in greater detail. As shown, a reduced volume area820is defined between wall652and annular ring612with bull nose760of driven clutch604extending into reduced volume area820through annular opening668. As mentioned before, this positions impeller blades762adjacent to annular opening668and thus adjacent to reduced volume area820. As driven clutch604is spun, a vacuum is created causing a suction of air through intake port630into the inner volume of CVT housing606. This incoming air cools the internal volume of the CVT, and the spinning of the drive clutch602including impeller blades710, exhausts the air through opening644and upwardly through exhaust duct810.

The CVT600is shown as coupled to the engine and the transmission inFIG. 26. CVT600is positioned such that exhaust duct610overlaps top rail portion100cwith exhaust port810projecting air downwardly towards engine200and the exhaust manifold452. Thus, as air is circulated through the CVT600, even though the air is heated by the cooling of the CVT, the exhaust air through duct810is still cooler than the temperature provided at the exhaust manifold and at the engine providing ample cooling of the engine and exhaust manifold.

With reference now toFIGS. 27 and 28, fuel tank850will be described as mounted to frame4. Fuel tank850includes an upper volume portion852which includes an integrated fuel pump854including a fuel hose856extending from fuel tank850to engine200. Pump854includes an automatic shut-off valve if the vehicle overturns to prevent engine200from continuing to operate and/or from fuel spilling. Fuel tank850further includes a fill spout at858for adding fuel to fuel tank850. Fuel tank850further includes a front volume portion860defined as a front nose862which can tuck under front bracket mount106, as described herein. Fuel tank850also includes a lower tank portion864defining underside support surfaces866. Fuel tank850is mounted together with seat900, as shown inFIG. 28. As depicted inFIG. 28, seat900is for a single rider.

Seat900includes front mount brackets902having a rearward bracket portion902acoupled to the seat900and a front mount tab902bwhich can be placed adjacent to flange870and against brackets108,110. Fasteners910can project through mounting tabs902b, flanges870and into registration with mounting apertures108aand110a. Snap mount tabs920couple seat900to crossbar112. As shown inFIG. 29, fuel tank850is mounted to rails100,102, with front angled wall872tucked within bracket106and nose portion862projecting from beneath bracket106. Further, rear wall874is shown as defining a radiused wall, scalloped out to define enough clearance to remove a spark plug from a top of engine200.

With reference now toFIGS. 29 and 30, airbox940is shown coupled to rails100,102, by way of mounting tabs942and fasteners944. A throttle body946is coupled directly to an intake port of engine200and is coupled to airbox940by way of a flexible bellows950. As shown inFIGS. 29 and 30, engine is positioned in an inclined direction towards a front of the vehicle and is generally centered between upper rails100,102, with a top of engine200positioned above the rails100,102. Airbox940is positioned rearwardly of engine200and coupled to a top of rails100,102, with the throttle body946positioned intermediate to engine200and airbox940.

With reference now toFIG. 31, airbox940is shown in an exploded manner to include lower airbox portion970, airbox lid972which includes integrated snorkel974, filter976, and breather tube978. Airbox lower portion970includes an intake duct980which couples to filter coupling982by way of clamp984. Thus as installed, filter976is positioned in box970coupled to coupler980with lid972positioned over the lower portion970and held in place by snap rings986. Breather tube978couples to the engine200to return unspent gasses into the airbox for recirculation.

With reference now toFIG. 32, battery1000is shown as installed at a front of ATV, directly to lower skid plate60. Skid plate includes front and rear struck tabs1002,1004(seeFIG. 5), and a struck anchor tab1006. As shown, a battery receiving area is defined between tabs1002,1004; tab1006and an inside surface of rail50b. A strap1010may be provided having a front hook1012engagable in a slot within tab1006, with strap1010wrapped around battery as shown inFIG. 32. An opposite end of strap1010includes a mounting tab1014which can be coupled to rail50bby way of fastener1016. Having battery1000mounted directly to the skid plate mounts the battery as low as possible within the vehicle, lowering the center of gravity of the overall vehicle for increased stability.

With reference now toFIG. 33, other systems of the ATV are shown, namely a front suspension system1020, cooling system1022, and electrical load center1024. As shown, suspension system1020includes a lower alignment arm1030coupled at brackets56at an inner end and to wheel hub1032at an outer end. Wheel hub1032is also coupled to a strut1036at a lower end and to shock tower124at an upper end.

Cooling system1022includes a radiator1040coupled to brackets130positioning radiator at the front of the vehicle for maximum cooling purposes. Load center1024is coupled to front bracket106including junction boxes containing fuses and relays as well as an engine control management system (not shown). A voltage regulator1042can be positioned in front of the radiator for maximum cooling purposes.

With reference now toFIGS. 34-37, steering system20will be described in greater detail. As shown inFIG. 34, steering system20includes steering post1050, power steering unit1052and steering linkage1054. With reference now toFIG. 36, bracket126retains bearing1060thereto by way of fasteners1062,1064. A pitman arm1070is positioned in bearing1060with a lower end1072positioned in bearing opening1074. Pitman arm1070includes an upper splined collar1080to be driven by motor1052as described herein. Upper plate1084is coupled to brackets1086by way of fasteners1088,1090. Bracket1084includes an opening at1092generally centered with splined collar1080. Power steering motor1052has a splined output shaft1200(FIG. 37) and is mounted to plate1084by way of fasteners1202received in threaded bosses1204. Steering arms1210(FIG. 34) may be coupled between pitman arm1070and link1214on strut1036.

With reference now toFIGS. 38 and 39, a modified vehicle can be profiled into a two passenger configuration by slightly elongating the frame to provide a frame4′. A two person seat is provided at16′ which is a one piece design including seat positions1300,1302. Seat16′ is mounted in an identical way using mounting clips902and clamps920. A seat back1304may be mounted by way of mounting bracket1306by coupling bracket1306to rails100,102, by way of fasteners1310.