Snowmobile

A snowmobile comprises a chassis with a front portion and a tunnel, and a power train unit supported by the chassis. The snowmobile further includes a plurality of ground-engaging members cooperating with the power train unit to operate the snowmobile. The plurality of ground-engaging members includes a pair of front skis and an endless track assembly. The track includes a wide track belt and the snowmobile body portions and chassis are adapted to fit the wide track belt. A rear rack assembly is positioned on a rear of the snowmobile frame and can support a passenger seat.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to snowmobiles and, more particularly, to wide track snowmobiles.

Generally, snowmobiles are available for various applications such as deep snow, high performance, luxury touring, and trail riding, for example. Another application for snowmobiles is the wide track version which has a 20″ track versus the standard 15″ track. Regardless of the application, certain structural components are common to many snowmobiles. For example, snowmobiles typically include a frame, a track assembly, a power train, skis, and at least one suspension system, as are illustrated in any of the following U.S. Pat. Nos. 7,353,898; 7,533,749; 7,694,768; 7,891,454; 7,854,285; 8,127,877; 8,490,731; 8,590,654; 8,944,204; 9,096,289; 9,428,232; and 9,446,810; the complete disclosures of which are expressly incorporated herein by reference.

One common area for snowmobiles generally relates to the overall architecture, where a frame includes a tunnel and a front chassis portion which retains the power train, and a front suspension that mounts skis to the frame. A drive shaft is typically mounted to the front chassis portion and includes drive sprockets for powering the belt. A chain case is also typically provided to transfer power from an engine or CVT to the drive shaft. Reference is made to U.S. Pat. No. 7,694,768 which shows a typical snowmobile drivetrain, the subject matter of which is incorporated herein by reference.

In the case of wide track snowmobiles, one common characteristic is to provide a wider tunnel to the track as the width footprint of the track is increased to 20″. A wider tunnel is provided to cover the wider belt. A front body typically surrounds at least the front frame portion to enclose the engine and other mechanical components.

SUMMARY OF THE DISCLOSURE

In one embodiment of the disclosure a snowmobile comprises a chassis having a front bulkhead and a tunnel, the front bulkhead including first and second cast clips which couple about a longitudinal mating axis; wherein the cast clips are asymmetric with the second cast clip being wider than the first cast clip.

In another embodiment of the disclosure, a vehicle comprises a frame; ground engaging members supporting the frame; a driver's seat supported by the seat; and a rear rack assembly coupled to a rear portion of the frame and positioned rearwardly of the driver's seat. The rear rack assembly comprises a platform coupled to the frame; a rack generally surrounding at least a portion of the platform and coupled to the frame; and a rear seat support coupled to the rack and positioned at a forward portion of the rack and rearward of the driver's seat.

In another embodiment of the disclosure, a snowmobile comprises a frame comprising a bulkhead and a tunnel; the tunnel comprising a center portion, side portions and a transition portion, the transition portion spacing the side portions away from the center portion, wherein the transition portion is arcuately formed to form an outer convex wall between the center portion and the side portions.

In yet another embodiment of the disclosure, a snowmobile comprises a frame; a powertrain coupled to the frame; a track coupled to the powertrain for propelling the vehicle; the powertrain comprising a power source and a transmission, the transmission having a housing with at least one shaft therein with gears of the transmission and an idle shaft coupled to the at least one shaft, the idler shaft extending through the housing; a brake rotor coupled to the idler shaft; and a brake caliper coupled to the frame and positioned around the brake rotor.

In a further embodiment of the disclosure, a snowmobile comprises a frame; a powertrain coupled to the frame at a forward portion of the frame; a radiator positioned forward of the powertrain and angled relative to a vertical axis; and a hood positioned over the radiator enclosing the front portion of the snowmobile.

In another embodiment, a snowmobile comprises a chassis having a front bulkhead and a tunnel; the tunnel having a center section and side walls; a structural member positioned at an end of the tunnel sidewall and between the sidewalls; and a tubular strengthening member coupled to the tunnel sidewall and to the structural member.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, which are described below. The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise form disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. For example, while the following description refers primarily to a snowmobile, it should be understood that the principles of the invention apply equally to other snow vehicles. While the present invention primarily involves a snowmobile, it should be understood, however, that the invention may have application to other types of vehicles, such as motorcycles, ATVs, utility vehicles, scooters, and mopeds.

Referring toFIG. 1an illustrative embodiment of a snowmobile10includes a chassis or frame12including a front frame portion14and a rear frame portion16. Front frame portion14is supported by front ground-engaging members, illustratively skis18, and rear frame portion16is supported by a rear ground-engaging member, illustratively an endless track20. Front skis18are operably coupled to a front suspension assembly22, and endless track16cooperates with a rear suspension assembly24. Snowmobile10also includes a seat assembly26including a driver's seat28and an optional passenger seat30as further described herein. A rear rack assembly32is positioned rearwardly of the passenger seat30and is coupled to the rear frame portion16as described herein.

Referring toFIGS. 1, 20 and 21, a power train unit40(FIG. 20) is covered by an outer body42(FIG. 1) and provides power to endless track20to move snowmobile10. As shown inFIG. 20, power train unit40is supported by front frame portion14and includes an engine44and a transmission46(FIG. 21). Transmission46as disclosed has high low gears as well as reverse. As shown inFIG. 1, snowmobile10also comprises a steering assembly48. With reference now toFIGS. 2-4, the frame12will be described in greater detail.

With reference now toFIGS. 2-4, frame12includes a bulkhead50coupled to a tunnel52. Bulkhead50comprises a front casting having right and left castings54and56. Castings54and56are commonly referred to as cast clips. As shown inFIG. 4, cast clips54and56couple along a longitudinal mating axis, shown as60. As shown, the cast clips54,56are asymmetric with the left cast clip56being wider than the right cast clip54. This is due to the fact that the right cast clip54is from a narrow track vehicle (15″) in order to minimize the number of new parts required. For example, the right cast clip is for a vehicle such as that shown for example in U.S. Pat. No. 8,490,731, the subject matter of which is incorporated herein by reference. The left cast clip56is a new component, and is wider than cast clip54.

With reference still toFIGS. 2-4, tunnel52is shown coupled to the bulkhead50. The right cast clip54is shown coupled to the tunnel52by way of a first transition piece66and the left cast clip56is coupled to the tunnel52by way of second transition piece68. Second transition piece68is also a component which is already available for a vehicle such as that shown for example in U.S. Pat. No. 8,490,731, the subject matter of which is incorporated herein by reference. As shown, an outer edge70of the first cast clip54is coupled to a first outer edge72of the tunnel, and an outer edge74of the second cast clip56is coupled to a second outer edge76of the tunnel. That is, first transition piece66couples the outer edge70of the first cast clip54to the outer edge72of the tunnel52, and the second transition piece68couples the outer edge74of the second cast clip56to the second outer edge74of the tunnel52. As shown, the first transition piece66flares outwardly to space the first outer edge72of the tunnel52from the outer edge70of the first cast clip54. This is to make up the width difference of the left cast clip56. As shown, outer edge72is spaced apart from outer edge70by a distance shown at80. The end result of this assembly is that the tunnel52is wide enough to accommodate the wide track belt of 20″. It should be understood that while the present disclosure relates to a wide track snowmobile of 20″ from a 15″ track, it is possible to use the present disclosure to modify a snowmobile from a range of approximately 12″ to a width of 28″.

With reference now toFIGS. 2-6, tunnel52will be described in greater detail. As shown, tunnel52is comprised of multiple parts coupled together, namely tunnel52is comprised of a center portion90, side portions92and a transition portion94. Transition portion94has also multiple functions.

First, the transition portion94is providing the 90° bend between the center portion90and the side portions92. Transition portion94is also providing a rounded corner at96defining a convex wall to provide a better ergonomic feel for the driver, as the driver's legs straddle the tunnel52. Transition portion94is also providing a heat exchange function where the transition portions have internal water passages98for cooling water to circulate and be cooled by the tunnel. The water circulates through the tunnel by inlet and outlet passages100, which couple to the engine44through hoses (not shown). The water circulates through internal channels98(FIG. 6), to make a U-shaped flow pattern in and out of the tunnel52to cool engine44. The channels extend along a substantial length of the tunnel52as shown best inFIGS. 2 and 3. This cooling function is more thoroughly described in our U.S. Pat. No. 7,353,898. Transition portion94is also providing a retention function having slots at106to receive a head of a fastener. Finally, transition portion94provides a coupling portion108having an extension108aforming a slot108b(FIG. 6) for receiving side portion92, as further described herein.

With reference now toFIG. 7, a cast coupler is shown at110which couples to the corner96of the transition portion94and includes a concave portion at112to overlie the corner96. Cast coupler110is coupled to the tunnel52by way of fasteners at114. Cast coupler110also includes a right-angled portion at116to couple to the tunnel52by way of fasteners at118. Cast coupler110also includes tube connectors120and122which couple corresponding frame tubes124and126. Cast coupler110also includes a tab at130to couple to a frame tube132.

With reference now toFIGS. 8-11, a rear of the tunnel is shown as including a tow ring attachment140which couples to an extruded close off142. (FIGS. 9-11). As shown inFIGS. 10 and 11, close off142is comprised of an extruded bar having an upper portion144, lower portion146and a trailing portion148having apertures148a. Lower portion146includes apertures146a(FIG. 11) and apertures146b(FIG. 10). Extruded close off142also includes a receiving opening150having apertures152. Opening150is a square machined hole for for the hitch receiver to slide into, although alternate shapes could also be used. As shown inFIG. 8, tow ring attachment140includes a tow ring bracket or pintle at158with a tow ring160where the tow ring bracket158couples to the extruded close off142by way of fasteners162, which couple with apertures152. Alternatively, the pintle158could be a square receiver/standard hitch receiver.

With reference now toFIGS. 12-14, a rear tubular strengthening member is shown at170which cooperates with side panel172which is positioned over side panel92of tunnel52. As shown inFIG. 13, rear tubular strengthening member170is comprised of tubular members174,175and176welded together to form a solid member. Tubular strengthening member170also comprises a front end176a, received in and forming an extension with, the running board tubular member178. Tubular strengthening member170extends rearwardly to an end of the tunnel52. Tubular strengthening member170also includes a portion extending upwardly at180and couplers182and184are provided for mounting to side wall92. Panel172includes a portion190which lies flush with side panel92and a horizontal portion192which is generally planar with the running board194. Tubular strengthening member170together with panel172help to strengthen the rear of the tunnel as the rear of the tunnel is a cantilevered portion which also requires strengthening because of the towing requirements. As shown inFIG. 14A, fasteners196are provided to couple with the extruded close off142and particularly into apertures146a(FIG. 11). It should be understood that tubular strengthening member170could also be a cast member.

With reference now toFIGS. 14B-14D, the rear tunnel portion is shown with rigified layers of material including wall portion190of panel172, side wall92, extension108, and a structural member in the form of strengthening strip198. As shown best inFIG. 14B, sidewall92is positioned within slots108b, and coupling portion184is positioned against wall92of side panel172. It should be appreciated thatFIG. 14Bis an end view of the left hand end of the tunnel and that the right hand side would be a mirror image of that shown inFIG. 14B. Fasteners196couples the layers of material shown inFIG. 14Btogether and traps them with extruded close-off142trapped therebetween. This provides a significantly strengthened rear tunnel portion for towing and carrying capacity.

With reference now toFIGS. 15 and 16, the front outer body42will be described in greater detail. As in other aspects of the snowmobile10, the present disclosure utilizes components from the narrower track vehicle and accommodates their usage in other components. The same is true for the outer body portion42as the nose portion200and hood202are from another vehicle model. Rather the vehicle front outer body42is widened by adding new fenders204and new side panels206.

With reference now toFIGS. 16 and 17, an air intake system220for snowmobile10is shown which includes plenum222, first duct portion224and second duct portion226, where duct226feeds into air cleaner230. Air cleaner230includes an upper portion232and a lower portion234where the lower portion has outlets236which feed to the throttle bodies (not shown) of engine44. The plenum222, ducts224,226and air cleaner lower portion234are all utilized from a prior snowmobile model, but in the embodiment disclosed, the engine needed to be moved leftwardly and thus the air cleaner upper portion232is notched at240by the distance that the engine needed to be shifted. In this manner, the entirety of the air intake system220, except for the upper air cleaner portion232could be utilized from the prior design. It should be appreciated that the air intake system could also be one of the air intake systems shown in U.S. Pat. No. 8,127,877 or US Publication No. 2015/0197313, the subject matter of which is incorporated herein by reference.

With reference now toFIGS. 18-20, an engine cooling system will be described in greater detail. As shown first inFIG. 18, engine cooling system is comprised of a radiator250and a shroud252. As shown, radiator250is positioned at an angle relative to a horizontal position where the angle is shown at254. Angle254is between 30 and 45° and as shown is approximately 37.5°. By placing the radiator at an angle, the angle of the radiator is designed to melt snow and pass it through the radiator to prevent a wall of snow and ice building up, preventing air from passing through the radiator. Thus, as shown best inFIG. 19, the radiator250and shroud252are nested around the exhaust system260where the radiator sits over a lower portion262of the exhaust system260and sits to the left of rearwardly extending portion264of exhaust system260. Shroud252includes a peripheral wall270extending at least partially around the shroud including a right-hand side portion272, a front portion274and a left-hand side portion276. Shroud270also includes an intake duct portion at280which feeds air in from the left hand side of the vehicle. As shown best inFIGS. 18 and 19, hood202conforms to the top of the shroud and also feeds air into the shroud whereby intake openings282(FIG. 15) feed air into the center of the shroud252and side opening284(FIG. 15) feeds air into the intake duct280.

With reference now toFIGS. 21-24, the braking system of the snowmobile10will be described in greater detail. With reference first toFIG. 21, a braking system is shown at290having a brake disc292and a brake rotor at294. Brake disc is coupled to a shaft of the transmission46such that braking the vehicle is transmitted through the transmission. More particularly, and as shown best inFIG. 23, where brake disc292is shown removed, transmission46includes an additional idler shaft296which drives the brake disc292. Three other shafts run transversely within the transmission46and would rotate on an axis300,302and304. Idler shaft296is positioned forward of all of the axes300,302and304to position the brake disc292out of the way of the rider toe hold310, which is best shown inFIG. 21. Idler296would be coupled to one of the three shafts of the transmission to drive the idler shaft296, such that braking the idler shaft would put a reverse torque the transmission and brake the vehicle10. As shown best inFIG. 22, brake disc292is in lateral alignment with toe hold310(shown in phantom) such that if brake disc292is not moved forwardly, the brake disc would crowd the space of the toe hold310. As shown best inFIG. 24, a guard320is coupled to the frame12and includes a rearwardly extending portion322to protect the brake disc292from an underside thereof.

With reference now toFIGS. 25-36, rear rack assembly32will be described in greater detail. As shown best inFIG. 25, rear rack assembly32is shown coupled to a rear portion of tunnel52and is profiled to carry a luggage carrier354.FIG. 26shows the rear rack assembly with the storage container354removed. As shown inFIG. 27, rear rack assembly32is comprised of a brace360, a platform362, a perimeter wall364, and a passenger seat support366which includes a coupler368.

As shown best inFIGS. 27 and 28, brace360is shown coupled to the top of the tunnel52where brace360includes laterally extending brace members370and longitudinally extending brace members372.FIG. 29shows the platform positioned on top of brace360where apertures376align with corresponding apertures378on brace360(FIG. 28). Perimeter wall364is shown positioned on top of platform362inFIG. 3, where wall364includes apertures at390which align with apertures376and378. Thus, the platform alone or the platform and wall364can be coupled directly to brace360by way of aligning the various apertures376,378and390and positioning a fastener therethrough to couple to brace360.

As shown best inFIGS. 30-32, rear rack assembly includes upper rails400and lower rails402, and struts404and406. As shown best inFIG. 30, struts404and406include mounting tabs408,409for mounting of the perimeter wall. Wall364includes supports410and412. A support wall420is coupled between the supports410,412and includes mounting tabs422,424. As shown best inFIGS. 33 and 34A, seat support366includes the coupler368mounted to it. Namely, coupler368includes mounting tabs430,432which couple to a bottom of seat support366by way of fasteners434. Coupler also includes L-shaped brackets440(seeFIGS. 33 and 34A) having apertures442. Thus, seat support366and coupler368can be attached to upper rail400by way of fasteners448positioned through apertures442and into upper rail400.

With reference now toFIGS. 34B-38, the use of the rear rack assembly32will be described in greater detail. As mentioned above, the rear rack assembly32can be used with just the platform362; with the platform362and peripheral wall364; or with the combination of the platform362, peripheral wall364and seat support366. ThusFIG. 38shows fasteners450which can be used to retain the platform362or platform and peripheral wall364to the brace360(FIG. 27). When the use of the seat support and additional passenger seat30is desired, the seat support366is attached as described above.

As shown best inFIG. 35, the seat support366includes a seat latch assembly470, having a latch opening at472. As shown best inFIG. 36, the bottom of passenger seat30has a latch pin480, which is received in the opening472(FIG. 35) to retain the seat in position. Passenger seat30also includes catches484which open forwardly and attach to a portion of the frame. The latch470and latch pin480are more fully described in U.S. Pat. No. 8,678,464, the subject matter of which is incorporated herein by reference.