Abstract:
An air box for a motorcycle including a motorcycle engine and a fuel tank. The air box includes a housing having an inlet configured to receive intake air into the housing and an outlet configured to direct the intake air from the housing to the motorcycle engine. A filter element is coupled to the housing and is configured to separate debris from the intake air. A mounting feature is configured to connect the housing below the fuel tank of the motorcycle.

Description:
BACKGROUND 
       [0001]    The present invention relates to a motorcycle. In particular, the invention relates to an air box for a motorcycle that mounts below the fuel tank of the motorcycle. 
       SUMMARY 
       [0002]    In one embodiment, the invention provides an air box for a motorcycle including a motorcycle engine and a fuel tank. The air box includes a housing having an inlet configured to receive intake air into the housing and an outlet configured to direct the intake air from the housing to the motorcycle engine. A filter element is coupled to the housing and is configured to separate debris from the intake air. A mounting feature is configured to connect the housing below the fuel tank of the motorcycle. 
         [0003]    In another embodiment, the invention provides a motorcycle including an engine, a fuel tank, and an air box. The fuel tank is configured to store fuel to be combusted in the engine. The air box is in fluid communication with the engine and configured to provide intake air to the engine. The air box includes a filter element to separate debris from the intake air. The air box is mounted below the fuel tank. 
         [0004]    In yet another embodiment, the invention provides a method of assembling a motorcycle. A motorcycle frame is provided and an engine is mounted in the frame. A fuel tank is mounted to the motorcycle frame. An air box is mounted below the fuel tank. An intake passage is provided through the air box in communication with the engine. 
         [0005]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a perspective view of a motorcycle of the present invention including an air box coupled to the fuel tank; 
           [0007]      FIG. 2  is a left side view of the motorcycle of  FIG. 1 ; 
           [0008]      FIG. 3  is a right side view of the motorcycle of  FIG. 1 ; 
           [0009]      FIG. 4  is an exploded view of a fuel tank, a fuel tank cover, and the air box assembly of the motorcycle of  FIG. 1 ; 
           [0010]      FIG. 5  is a front view of a fuel tank and air box assembly of the motorcycle of  FIG. 1 ; 
           [0011]      FIG. 6  is a side view of the fuel tank and air box assembly of  FIG. 5 ; 
           [0012]      FIG. 7  is a top view of the fuel tank and air box assembly of  FIG. 4  with a cutaway showing the inside of the fuel tank; 
           [0013]      FIG. 8  is a cross-sectional view of the fuel tank and air box assembly, taken along line  8 - 8  of  FIG. 6 ; 
           [0014]      FIG. 9  is a cross-sectional view of the fuel tank and air box assembly, taken along line  9 - 9  of  FIG. 7 ; and 
           [0015]      FIG. 10  is a bottom view of the fuel tank of  FIG. 4 . 
       
    
    
       [0016]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as 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 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. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
       DETAILED DESCRIPTION 
       [0017]      FIGS. 1-3  illustrate a motorcycle  20  including an engine  24  and an intake system  28  for supplying intake air to the engine  24 . The intake system  28  includes an air box assembly (simply referred to hereinafter as the air box  32 ), a throttle assembly  34  between the air box  32  and the engine  24 , and a filter element  35  positioned in the air box  32 . The motorcycle  20  also includes a fuel tank  36  configured to store a volume of fuel for the engine  24  and a fuel tank cover  38  for covering the top and sides of the fuel tank  36 . The fuel tank  36  includes a filler assembly  42  for accessing the inside of the fuel tank  36  to refuel, etc. The fuel tank  36  includes a longitudinal channel  36 A (see  FIGS. 5 and 10 ), which receives a portion of the motorcycle frame  44 , to which the fuel tank  36  is mounted. 
         [0018]      FIG. 4  is an exploded assembly view illustrating the air box  32 , the fuel tank  36 , the fuel tank cover  38 , and associated components that make up the tank and air box assembly  46 . The air box  32  includes a housing  47  having an inlet opening  48  configured to receive intake air from the atmosphere into the housing  47  and an outlet opening  49  ( FIG. 9 ) configured to supply the intake air to the throttle assembly  34  and the engine  24 . The housing  47  defines an intake passage for intake air entering the engine  24 . The fuel tank cover  38  is assembled with the fuel tank  36  via threaded fasteners (not shown) that engage an assembly ring  50  adjacent the filler assembly  42 . The fuel tank  36  includes a plurality of mounting features  54  for further securing the fuel tank cover  38  thereto. The mounting features  54  are configured to receive adhesive strips (not shown). Alternate methods and components for securing the fuel tank cover  38  to the fuel tank  36  are also within the spirit and scope of the invention. 
         [0019]    With continued reference to  FIG. 4 , the fuel tank  36  includes a recess  58  in a bottom portion thereof. Referring to  FIGS. 6 and 10 , the recess  58  includes a surface  59  (i.e., recessed surface) recessed from a lower surface  60  of the fuel tank  36 . The recess  58  is positioned on a side of the fuel tank  36 , extending laterally to a side wall  62  of the fuel tank  36 . The recess  58  is configured to receive the air box  32 . When assembled with the fuel tank  36 , as best shown in  FIGS. 5 and 6 , the air box  32  is at least partially “tucked” or “recessed” into the fuel tank  36  by way of the recess  58 . The housing  47  includes an upper surface  64  configured to lie adjacent to the recessed surface  59 . The fuel tank  36  further includes mounting locations in the form of pockets or mounting recesses  66 A,  66 B,  66 C, and  66 D (all of which are shown in  FIG. 10 ). The air box  32  includes mounting features in the form of mounting flanges  68 A,  68 B,  68 C, and  68 D formed integrally (e.g., molded as a single piece) with the housing  47 , extending upwardly from the upper surface  64  thereof. The mounting recesses  66 A,  66 B,  66 C, and  66 D are formed in the fuel tank  36  to receive the mounting flanges  68 A,  68 B,  68 C, and  68 D of the air box  32 , respectively. 
         [0020]    Referring to  FIGS. 4 and 8 , a first bushing  72 A is positioned in a first bore  74 A in the fuel tank  36 . The first bore  74 A is formed in the fuel tank  36  between the mounting recess  66 A and the mounting recess  66 C. A second bushing  72 B is positioned in a second bore  74 B in the fuel tank  36 . The second bore  74 B is formed in the fuel tank  36  between the mounting recess  66 B and the mounting recess  66 D. The bores  74 A and  74 B in the fuel tank  36  are not open to the interior volume of the fuel tank  36 , but rather are formed in one or more solid portions of the fuel tank  36  as best shown by  FIG. 9 . A first fastener  76 A is configured to pass through the first bushing  72 A and through holes  78 A and  78 C in the respective mounting flanges  68 A and  68 C. A second fastener  76 B is configured to pass through the second bushing  72 B and through holes  78 B and  78 D in the respective the mounting flanges  68 B and  68 D. 
         [0021]      FIGS. 5-10  illustrate features of the tank and air box assembly  46  with the fuel tank cover  38  removed for clarity. The fuel tank  36  is formed with a ridge  80  as shown in  FIGS. 5 and 6 . When the motorcycle  20  (or at least the tank and air box assembly  46 ) is fully assembled, a lower edge  82  of the fuel tank cover  38  abuts or lies adjacent to the ridge  80  of the fuel tank  36 , creating the look of a linear seam along the side (see  FIGS. 2 and 3 ). With the air box  32  mounted to the fuel tank  36 , a ridge  86  of the air box  32  also abuts or lies adjacent to the lower edge  82  of the fuel tank cover  38 . The ridge  86  is formed to follow the contour of the lower edge  82 , creating the look of a linear seam that is continuous with the seam between the lower edge  82  and the ridge  80  in the fuel tank  36 . Thus, the air box  32  is visually integrated into the appearance of the fuel tank  36  and fuel tank cover  38 . 
         [0022]    As best shown in  FIG. 8 , the mounting flanges  68 C and  68 D receive threaded inserts  90 A and  90 B, respectively. When the air box  32  is positioned with the mounting flanges  68 A,  68 B,  68 C, and  68 D in the respective mounting recesses  66 A,  66 B,  66 C, and  66 D, the fastener  76 A is inserted through the mounting flange  68 A, through the bushing  72 A, and into the threaded insert  90 A in the mounting flange  68 C. Likewise, the fastener  76 B is inserted through the mounting flange  68 B, through the bushing  72 B, and into the threaded insert  90 B in the mounting flange  68 D. The fasteners  76 A and  76 B are threaded into the threaded inserts  90 A and  90 B, such that the air box  32  is fastened securely with respect to the fuel tank  36 . Washers  92 A and  92 B are positioned between the outer faces of the mounting flanges  68 A and  68 B and the heads of the fasteners  76 A and  76 B, respectively. 
         [0023]    The fasteners  76 A and  76 B directly engage the air box  32 , which then hangs from the first and second bores  74 A and  74 B in the fuel tank  36 . In other embodiments, the mounting features of the air box  32  can be coupled directly or indirectly to the mounting locations of the fuel tank  36  in other manners. For example, in some embodiments, fasteners engage a threaded portion or insert in the fuel tank  36  rather than threading into the mounting features. The air box  32  can also be coupled to the fuel tank  36  with alternate types of fasteners, such as clamps, ties, snaps, hooks, adhesive, etc.