Patent ID: 12258077

DETAILED DESCRIPTION OF THE DRAWINGS

With reference first toFIGS.1-10, the vehicle of the present invention will be described. As shown, the vehicle is generally depicted as reference number2which includes front wheels4and rear wheels6. Front wheels4are comprised of rims8and tires10, whereas wheels6are comprised of rims14and tires16. Wheels4and6support a vehicle frame which is shown generally at20and which supports a seating area22comprised of a driver's seat24and a passenger seat26. A cab frame is shown at28and generally extends over the seating area22to protect the passengers from such objects as tree branches, etc. A 6-point shoulder harness30(FIG.5) is also positioned over each of the seats24,26although it is only shown in the figures as positioned over the driver's seat24for clarity. A passenger grab bar32is provided for the passenger in seat26. As best shown inFIG.2, vehicle2further includes a steering assembly at34for steering front wheels4whereby the steering assembly34includes a steering wheel36which is both tiltable and longitudinally movable as described further herein.

Vehicle2further includes a front suspension at40(FIG.2), which in the present disclosure is a double A-arm suspension and further includes a rear suspension42, which as shown in the present disclosure is a trailing arm-type suspension. A radiator46is provided for cooling purposes of the powertrain. As shown best inFIGS.3and4, powertrain is comprised of engine50, a continuously variable transmission (CVT)52(FIG.4) and a shiftable transmission76(FIG.7) which is operated by a shifter assembly60(FIG.5). In a preferred version of the present invention, the vehicle is a four-wheel drive vehicle including a front angled gear drive70(FIG.9) having front stub shafts72coupled to the gear drive70for driving the front wheels4. A rear angled gear drive76(FIG.7) is provided to drive half shafts78which drives rear wheels6. Finally, and with respect toFIG.10, vehicle2includes an air intake system80, an exhaust system82and a CVT cooling system84.

With reference now toFIGS.11-13, frame20will be described in greater detail. With reference first toFIG.11, frame20is comprised of outer frame tubes100and inner frame tubes102. Outer tubes include a longitudinally extending portion104and vertically extending portions106. Frame tubes102include horizontally extending portions108and vertically upstanding frame tubes110. Outer frame tubes112extend forwardly and generally parallel with frame tubes104and couple to upright frame tubes114. Frame tubes114support a U-shaped frame tube116having couplers118to which cab frame28is attached. U-shaped tube116is supported by a front frame portion120comprised of a fixed front frame portion122and a removable front frame portion124. Fixed front frame portion122is comprised of three sets of upwardly extending frame tubes, namely frame tubes126, frame tubes128and frame tubes130. Fixed frame portion also includes transverse frame members132,134and136. Finally, fixed front frame portion122is comprised of longitudinal tube portions140.

With reference still toFIG.11, a seating support is generally shown at150including transverse frame tubes152and154and longitudinal frame tube pairs156and158, which support the seats24,26respectively as described further herein. A tunnel portion160is provided between the frame tube pairs156,158and allows for routing of cabling, etc. from the front of the frame to the rear of the frame. A belly pan164is positioned under the seat frame150to protect the riders from rocks and dust as the vehicle traverses various terrain. It should be noted that belly pan164may also be viewed inFIG.8from an under side of vehicle2.

With reference now toFIGS.11-13, a rear of the frame will be described. With reference first toFIG.11, a powertrain support area170is provided including rearwardly extending frame tubes172and upwardly extending frame tubes174. Frame tubes174extend upwardly and include brackets176, to which a rear portion of cab frame28is coupled, as further described herein. With reference now toFIG.12, a cab frame support area180is provided having a transverse tube at182, which couples to forwardly projecting tube portions174aof frame tubes174. Transverse tube182is also coupled to frame tubes106,110. Brackets186couple to both frame tubes174a,182and include a base portion188and an upper plate portion190having apertures192therethrough with fasteners194on an inside thereof for receiving a bolt, as described further herein.

With reference now toFIGS.12and13, a utility bed support area200will be described in greater detail. Support area200includes transverse tube202extending between upright frame tubes110and a rear plate206extends transversely of and is coupled to frame tubes174. A channel-shaped bracket208is coupled to plate206, and together with frame tube202, supports longitudinally extending frame tubes210. As shown inFIGS.12and13, frame tubes210may be held in place by way of fasteners220and222.

With respect again toFIG.11, door support brackets are provided on both the driver and passenger side, whereby a bracket224and226extend forwardly from tube106on the driver's side and a bracket224and238extend forwardly on the passenger side.

With reference now toFIGS.14-18, a first embodiment of the removable front frame portion124will be described. As shown inFIG.14, a coupler230is provided which couples to frame tubes108,109and130and which provides an interface to the removable frame portion124as described herein. With reference toFIGS.15and16, the removable frame portion124includes longitudinal tube portions234which couple to a front plate236. Plate236includes an upper bracket portion238having apertures at240. An L-shaped bracket arm244is coupled between tubes234and plate236. L-shaped bracket244includes an upper arm portion250providing a mount for differential70. A rear coupler254is provided which is complementary with couplers230and is coupled to frame tubes234. Coupler254can be a cast metallic member such as aluminum and could be attached to tubes234by way of fasteners, industrial adhesives and/or welding.

As shown best inFIG.16, mounting brackets260and262are coupled directly to frame tubes234for mounting of the lower A-arms of the front suspension40. Brackets264and266(FIG.15) are coupled to frame tubes140for mounting the upper A-arms of the front suspension. Fixed front frame portion122includes a mounting bracket268(FIG.15) having mounting apertures at268a.

With reference now toFIGS.16-18, couplers230and254will be described in greater detail. As shown best inFIG.16, coupler254includes a semi-circular opening270providing clearance for a drive shaft that couples to shaft272of differential70. Coupler254also includes indents276and apertures at278.

As shown inFIGS.17and18, couplers230include a base portion280each having faces282and284, each providing a set of coupling pegs286,288respectively, arranged in a circular pattern. Each set of the coupling pegs286,288are sized to be received in the inside diameter of tubes109,108respectively, whereby the tubes are fastened to couplers230. Couplers230further include a semi-circular upstanding coupler portion290which couples to frame tubes130. Tubes108,109and130could be held in place by additional fasteners or could be welded or held in place by industrial adhesives. L-shaped arms300also extend upwardly from body portion280and include horizontally extending walls302having pegs304and apertures306. It should be appreciated that pegs304correspond with indents276of coupler254and that apertures306align with apertures278when couplers230,254are properly aligned. As shown best inFIG.18, couplers230further include forwardly facing walls310having a through hole312and square apertures314.

With reference now toFIGS.19-23, an alternate removable front frame portion320will be described in greater detail. As shown, removable front frame portion320is similar to removable front frame portion124with the exception that L-shaped brackets244are not included. Rather, brackets322for mounting the differential are coupled to frame tubes132and140, as in this embodiment, the differential70is not removed with the removable front frame portion320. Couplers330couple to frame tubes108,109and130in a similar manner as described above.

As shown inFIGS.22and23, couplers330include a base portion332each having faces334and336, each providing a set of coupling pegs338,340respectively. Each set of the coupling pegs338,340are arranged in a circular pattern and sized to be received in the inside diameter of tubes109,108respectively, whereby the tubes109,108are fastened to couplers330. Couplers330further include a semi-circular upstanding coupler portion342which couple to frame tubes130. Tubes108,109and130could be held in place by additional fasteners or could be welded or held in place by industrial adhesives. L-shaped arms350also extend upwardly from body portion332and include horizontally extending walls352having pegs354and apertures356(FIG.23). It should be appreciated that pegs354correspond with indents276of coupler254and that apertures356align with apertures278when couplers230,254are properly aligned. As shown best inFIG.22, couplers230further include forwardly facing walls360having a through hole362and square apertures364.

With reference now toFIGS.24-26, a removable bearing assembly370will now be described. As shown best inFIG.24, removable bearing assembly370is shown attached and spanning the longitudinal portions108of frame tubes102(FIG.11). As shown, frame tubes108include brackets372for coupling bearing assembly370to frame tubes108. Removable bearing assembly370includes a channel-shaped support374having a bracket376mounted thereto. As shown best inFIG.26, bracket376includes upper support walls378and a recessed wall at380. Threaded openings are provided at382which receive fasteners384.

A bearing386is provided having an outer frame portion388with flanges at390having mounting apertures392. As shown, drive shaft400includes a front drive shaft portion402and a rear drive shaft portion404, where front drive shaft402includes splined outer shaft406and where rear shaft404includes a universal joint408having an internal spline at410. It should be appreciated that front shaft portion402extends forwardly to couple with front differential70(FIG.14) and where rear drive shaft portion404extends rearwardly and couples with transmission56(FIG.7). As shown best inFIG.26, bearing386includes an inner rotatable bearing420, such that when in the fully assembled position ofFIG.24, surface422of front drive shaft portion402and surface424of rear drive shaft portion404engage bearing portion420, with the splined shaft406fully inserted into the splined coupling410.

Thus, when in the fully assembled position ofFIG.24, and when removal of the drive shaft is necessary for service purposes, the belly pan164(FIG.8) is removed which provides access to the removable bearing assembly370. Removal of fasteners412from their corresponding fasteners414on bracket372allows channel374to drop downwardly, such that the splined shaft406and splined coupling410disengage, allowing for removal of both drive shaft portions402,404.

With reference now toFIGS.27-29, cab frame28will be described in greater detail. As shown, cab frame28generally includes frame tubes430, cross tubes432, clamp assemblies434, cross tube436, clamp assemblies438and pillar portions440. As shown best inFIG.28, frame tubes430are shown including a front portion444having a coupler at446, a central portion448and a rear portion at450, including a downwardly extending portion451having couplers at452. Each of the front444, center448, rear450and downwardly extending451sections are separated by an angled portion at456,458and459. Cross tubes432and436include apertures at460and462.

Clamp assembly434further includes upper and lower clamp halves470and472, where each clamp halve includes a channel476having a radiused portion478and a generally straight section at480. The radiused section478positions on the underside of angled portion456, and the straight portion480receives tube portion444. The upper clamp portion470is a mere image of clamp portion472to receive an upper portion of the radiused section456and front section444. Clamp portion470further includes an embossed section at486having apertures at488. An arcuate corner at490is provided which matches the radius of the cross tube432. While upper and lower clamp halves470and472are shown exploded away from frame tubes430, it should be understood that they are welded together.

Inserts494are provided for insertion through an upper section and lower section of apertures460, where each insert includes a head portion500with tubular sections at502and with apertures504extending through the insert494. Thus, inserts494are positioned in apertures460with the head portion500positioned on the outside of cross tube432and with the tubular portions504extending into the apertures460. Clamp halves470,472are then positioned over the tubes430with apertures488in alignment with apertures504, whereupon fasteners510may be received through apertures488and to receive fasteners512at the opposite end thereof.

Cross tube436is coupled to frame tubes430in a substantially identical manner as described above with respect to cross tube432, where clamps438include clamp halves520,522, and inserts524include a head portion526, tubular portions528and apertures530extending therethrough. Tubular portions528of inserts524are positioned into apertures462of cross tube436, whereupon clamp halves520and522may be positioned above and below frame tubes430and cross tube436. Fasteners534may be positioned through apertures536of clamp halve438to receive fasteners538after fasteners534pass through clamp halve522. The stack up of the inserts524against each other within the cross tube436is shown inFIG.29, whereby the inserts524are shown positioned through cross tube436, such that the inserts abut each other and prevent the crushing of cross tube436. Meanwhile, clamp halves520and522are shown positioned over inserts524with fasteners534,538retaining the clamp halves520,522and frame tubes430and cross tube436together. It should also be appreciated that the cross sectional view through cross tube432will look substantially identical to the cross section ofFIG.29, with the exception of the direction of front section444of tubes430.

Pillar440is shown best inFIG.28as including an inner pillar portion540and an outer pillar portion542. As shown, inner pillar portion540includes an upper flange portion at544having apertures546. Inner pillar portion540also includes a lower aperture at548. Outer pillar portion542also includes an upper flange portion550with apertures at552and lower apertures at554. Inner and outer pillar portions540,542align with each other as shown inFIG.27, such that apertures546and552are aligned. This also aligns aperture548with the left-most aperture554. A bracket560(FIG.28) is coupled to each side of frame tubes430whereby fasteners564are receivable through apertures552,546and562. It should also be appreciated that fasteners (not shown) are receivable through apertures554of outer pillar portion542and received through apertures192(FIG.12) for coupling with fasteners194. This couples the pillar portions540and542to the frame tubes430and to the frame bracket190(FIG.12).

It should be appreciated from the above description that the frame tubes430are continuous one-piece members with bends at456,458and459to define the frame tubes as shown inFIG.28. Also, the inner and outer pillar portions540,542could be stamped and formed metallic members or could be a cast material such as a cast aluminum.

With reference now toFIGS.30-32an alternate cab frame is shown at570which can be used in the place of cab frame28as previously described with reference toFIGS.27-29. Cab frame570generally includes longitudinal tubes572, cross braces574,575, front clamps576, rear clamps578and pillar members580. As shown inFIG.31, tubes572include forward portions580, center portions582, rear portion584and angled portion586. A bent portion588is positioned between tube portions580and582; a bent portion590is positioned between tube portions582and584; and a bent portion592is positioned between tube portions584and586. A coupler594extends from tube portion580and a coupler596extends from tube portion586.

Clamp members576are similar to clamp members434and include clamp halves600,602. Clamp halves600and602are identical to clamps470,472with the exception that clamps600,602include an embossed section at604including apertures at606. Cross tube574includes an insert at610having apertures at612. Clamp halves600,602clamp to tubes572by way of fasteners614positioned through apertures606,612and receiving fasteners616. While upper and lower clamp halves600and602are shown exploded away from frame tubes572, it should be understood that they are welded together.

Clamps578include clamp halves620,622and are substantially similar to clamp halves600,602having embossed sections624and apertures at626. Inserts630are identical to inserts610and have apertures at632. In a like manner, clamps578include fasteners636,638to join the tubes572and cross tube575together in the configuration ofFIG.30. As shown in the cross sectional view ofFIG.32, inserts630include a body portion640for receipt of embossed sections624. A reduced diameter portion642is positioned within cross tube575and can be held in place by such known techniques as fasteners, welding or industrial adhesives.

With reference now toFIG.31, pillar580will be described in greater detail. As shown, pillar portion580is a substantially triangular configuration having an inner surface with substantially cylindrical insets at650profiled to receive embossed sections652on tube members572. Fasteners654are received through embossed members652and are received in threadable openings656. A lower end of pillar member580includes extensions660having apertures662which align with apertures192(FIG.12) for coupling of pillar portion580to bracket portion186. Pillar portion580includes a forwardly facing aperture664having a threaded lug666in alignment with aperture664. Aperture664could be used for mounting a retractor in the event a 3-point harness is desired as opposed to the 6-point shoulder harness30(FIG.5). Fastener assembly668could be provided for accessory mounting directly to the cab frame570.

With reference now toFIGS.32A-32C, another embodiment of cab frame is shown at1250which can be used in the place of cab frame28or570as previously described with reference toFIGS.27-32. Cab frame1250is similar to cab frame570and includes like longitudinal tubes572, cross brace574, and front clamps576. The rear clamps1252, rear cross brace1254and pillar members1256are different and will be described herein.

As shown best inFIG.32B, rear clamps1252include a partially cylindrical member1260having apertures at1262, which as shown are complementary with embossed sections652so as to receive embossed sections652therein. Rear clamps are either welded over embossed sections or are held in place with industrial adhesive or other known fastening techniques. Rear clamps1252further include integrated couplers1266which are substantially similar in configuration as couplers594,596. Cross tube1254includes a tube1270having couplers1272at each end thereof which are complementary with couplers1266. Fasteners1274,1276attach the couplers1266,1272together, and resultantly couple cross brace1254to longitudinal tubes582. As shown in the cross sectional view ofFIG.32C, inserts1272include a body portion1280and a reduced diameter portion1282positioned within cross tube1270and can be held in place by such known techniques as fasteners, welding or industrial adhesives. It should also be understood that front cross brace574could be constructed such as rear brace1254, together with rear clamps1252.

With reference again toFIG.32B, pillar portion1256will be described in greater detail. As shown, pillar portion1256is similar to pillar portion580and includes a substantially triangular configuration having an inner surface with substantially cylindrical insets at1290profiled to receive embossed sections652on tube members572. Fasteners1292are received through embossed members652and are received into threadable fasteners1294. A lower end of pillar member1256includes extensions1296having apertures1298which align with apertures192(FIG.12) for coupling of pillar portion580to bracket portion186.

With reference still toFIG.32B, pillar portion1256includes a forwardly facing aperture1300having a threaded lug1302in alignment with aperture1300. Aperture1300could be used for mounting a retractor in the event a 3-point harness is desired as opposed to the 6-point shoulder harness30(FIG.5). As in the case of pillar portion580, pillar portion1256could be a forging or casting, such as aluminum or other strength metal.

With reference toFIGS.33-37, a rear utility bed670of the present invention will now be described. Utility bed670is positioned within a rear body portion672, such that utility bed670is defined as a removable tub which can be inserted and removed from the vehicle when desired by the operator. As shown best inFIG.34, the body portion672includes an upper platform portion674having an opening676therethrough formed by an upper perimeter wall678defined by a front portion678a, angled portion678b, side portion678c, rear angled portion678dand end portion678e. Body portion672is supported by the cross tube182of the frame, as best shown inFIG.35.

As shown inFIGS.36and37, removable tub670includes a floor portion680which forms a perimeter around the inside of removable tub670, as best shown inFIG.37. A raised portion682is defined with a pattern of channel sections684which in this embodiment extend in V-shaped channels angled rearwardly. Removable tub670includes a front wall690, angled front walls692, side walls694, angled rear walls696and a rear wall698. As shown best inFIG.36, removable tub670also includes an upper perimeter wall700having a front lip at702, angled side lips704, side lips706, rear angled lips708and rear lip at710. It should be appreciated that the removable tub670is slidably received in the opening676(FIG.34) of the rear body portion672and that the perimeter wall700of the removable tub is supported by the perimeter wall678and longitudinal frame tubes210(FIGS.13and35). The removable tub670can be latched in place by way of quarter turn locking members716having handles718, rotating latch members720.

The removable tub670has defined drain holes, namely two drain holes724at the rear thereof (FIGS.35and36) and two at the front thereof at726(FIGS.35and37), such that the channel680feeds into the openings724,726for drainage. It should also be noted that the drain holes724,726are positioned such that the location of the water draining downwardly does not contact any hot surfaces or items of the vehicle that could be damaged by the water, such as electrical controls of the vehicle.

Finally and with respect toFIG.33, the combination of the tub portion670and the rear body portion672, define a stepped area730by way of the combination of the perimeter wall700and an inner wall732. The stepped are730is defined such that a distance between opposing walls732of the rear body portion672is greater than a diameter of one or both of the wheels4,6; and such that a distance between opposing walls694of the tub portion670is less than a diameter of one or both of the wheels4,6. This allows for the storage of a spare wheel on the stepped area730.

With reference now toFIGS.38-45, a seating adjustment mechanism740will be described. As previously described, the driver's seat24and passenger seat26are coupled to a seat frame150. As described herein, seat adjustment mechanism740couples the seats24,26to the seat frame150, while allowing them to move in a fore-and-aft direction, as well as to tilt. As shown best inFIG.40, the seat adjustment mechanism740comprises a longitudinally movable track system742and a seat mount744coupled to the track system742. As described herein, the longitudinally movable track system742moves along the pairs of tubes156and158.

With reference now toFIGS.43and44, the track system742includes two channels748which are virtually identical and include rollers750(FIG.44, as shown four rollers750per track) which are held in channels748by way of fasteners752. As shown inFIG.44, the tracks are shown disposed without the longitudinal tubes156, but it should be appreciated that the longitudinal tubes156would be positioned within the channels748and intermediate the pairs of rollers750, such that channel748would move fore-and-aft under the cooperation of rollers750on either side of tubes156. In addition to the fasteners752, and as best shown inFIG.44, each channel748includes a post754which provides a spacer between the plates of the channel748and which receives one of the fasteners752therethrough to attach a bracket756having an elongate aperture at756a, as will be described further herein.

As shown best inFIG.43, one of the longitudinal tubes156includes a plurality of longitudinally spaced openings758for locking the channels748in various longitudinal positions. As shown best inFIG.44, one of the channels has a cutaway portion at760coupled to an actuator762, and a locator764(FIG.43) is positioned between a rod766and the cutaway760, where pegs768can align with the spaced openings758. Thus, when actuator762is moved in the direction of arrow770inFIG.44, rod766moves pegs768away from openings758, whereupon the channels748may move along the longitudinal tubes156under the cooperation of rollers750. As the cutaway760acts as a spring, release of the actuator762moves the pegs back to its original position and into alignment with two of the openings at750to lock the seat in a longitudinal position. The steady state position of the pegs768is in a locking position within two selected openings758. Although the locator764is shown with two pegs any number may be used.

With reference again toFIG.43, the tilt mechanism744includes inner frame members780and outer frame members782, where each pair of frame members780and782are coupled at a front end thereof by pegs784and at a rear thereof by way of a spaced rod786. The inner and outer frame members include U-shaped openings at788as described herein. Tilt mechanism744is coupled to channels748by way of upper and lower hinge pairs790,792whereby the hinge pairs reside between the frame members780,782on each side and apertures794and796align with threaded posts798. Fasteners800can then be positioned over upper hinge790to couple the hinge pairs790,792to the channels748. Each of the hinge pairs790,792includes an arcuate configuration at802and804allowing the rotation of the rod786relative to the hinge pairs790,792. This allows the pair of frame members780,782to rotate or tilt relative to the channels748. This also allows the tilt mechanism744to move with the longitudinal movement of the track member742along longitudinal tubes156.

The tilt mechanism also includes a locking device to hold the seats24,26in various tilt positions. This locking device is generally shown at810(FIG.43) to include a spacer rod812, a bearing814, a compression spring816, a lock device818, a rotatory cam820, an actuator822and an elongate fastener824. Spacer rod812is coupled to channels748by way of flanges830coupled to a top of each channel whereby apertures832are positioned over threaded members836and fasteners838couple the spacer rod812to the channel members. As shown inFIG.43, outer frame member782includes an extending portion848having serrated teeth at850. Coupler818includes complementary serrated teeth on an inside surface thereof and a rotary cam face854on an outer surface thereof, that is complementary with rotary cam820. The extension portion848is positioned between bearing814and spring816, such that compression spring816presses coupler818outwardly under spring pressure when rotary cam820is not engaged.

Actuator822is coupled to the assembly810by positioning fastener824through the end of the actuator822, through rotatory cam820, through coupler818, through compression spring816, through extension member848, through bearing814and through tube812. Fasteners860,862couple the assembly810together. Thus, when actuator member822is rotated, the rotary cam releases the compression against the extension848and the tilt mechanism744may rotate between extreme contact positions with slot870of extension848and the fastener824. When the user positions the seat in the proper tilt position, actuator822is activated to provide contact between the rotary cams bringing the coupler818and the serrated teeth into contact to lock the seat into position.

As shown inFIGS.41-43, the seat24may also be locked to the tilt mechanism744. A shown, tilt mechanism744includes two latches880(FIG.42) having apertures882coupled to openings884(FIG.43) of frame members780. Each of the latches includes a latch clasp at886, as described herein. As shown inFIG.42, seat24includes a seat base890having slotted openings at892and a locking rod at894. As shown best inFIG.41, locking rod894extends across and under the seat base890. To attach seat24, the two slots892may be positioned over the tubes784and the seat may be rotated downwardly such that rod894is latched into place with the clasps886over a top of the rod894, and with the rod positioned in a saddled fashion in the openings788, as shown inFIG.41.

As shown inFIG.45, a side view of the vehicle shows that the seat adjustment mechanism740has achieved both a tilt and longitudinal movement of seats24and26with little vertical movement upwardly, advantageously maintaining the center of gravity as low as possible in the vehicle, as the rider's weight in positioned in the seat. This is due to the construction of the tilt mechanism being integrated into the track system, as well as the rollers750being positioned along sides of the longitudinal tubes156.FIG.45also provides a view of the fuel tank898which has a portion898abelow the seat26and a portion898brearward of the seat.

With reference now toFIGS.46-49, the shoulder harness30for the passengers will be described. As shown best inFIG.46, harness30is generally shown as a belt system900and including a single retractor902coupled to cross tube152. As shown, the retractor902is coupled to the harness belt900which overlaps seat24, as described herein. With reference now toFIG.49, cross tube152includes a bracket906coupled thereto, whereby retractor902can be coupled to bracket906which positions retractor forward of, and below, the seat24. This provides the weight of the retractor902at a position low in the vehicle to lower the center of gravity of the overall vehicle2. The retractor includes a single belt910which feeds rearwardly over a belt guide912(FIG.49) which is also coupled to cross tube152. Belt guide912includes guide walls914defining a belt passageway at916over which the belt910may move in a fore-and-aft direction.

As shown inFIG.48, a strap loop is provided at920having a retainer922coupled to cross tube152which is rearward of the seat24. Strap loop920further includes a loop ring924through which belt910is fed. Belt910extends upwardly forming a Y-configuration having two belt portions extending upwardly over the seat, namely belt portions926and928. As shown best inFIG.46, belts926and928extend upwardly through another set of loops930coupled to cross tube182, where loops930are identical to loops920to guide the belts926and928over left and right shoulders of the driver, respectively.

With reference still toFIG.46, harness30further includes a lap belt940including belt portion942coupled at one end to a bracket944attached to frame tube112, and at the other end, to a buckle946having a release button948. An opposite lap belt950includes a tongue952which may couple with buckle946to hold the lap belts942,950in a connected condition. As shown best inFIG.47, lap belt portion950couples at the opposite end to a clasp956attached to cross tube152. As shown in bothFIGS.46and47, belt portions926and928include connecting portions960to couple the belt portions926and928to buckle946and tongue952respectively. The lower end of belt system900includes belt portions960and962which individually couple to the brackets756(FIGS.46and47). As belts926and928are directly coupled to the retractor902, and where the ends of belt portions960and962are coupled to the seat attachment mechanism740, the belts926and928are self-adjusting with the movement of the seat either in the fore-or-aft direction. As the lap belts942,950are coupled directly to the frame at944and956(FIGS.46and47), these belts may need to be readjusted for various fore-and-aft positions. It is anticipated that all or some of the belts would include tightening mechanisms to tighten or loosen the belts.

By providing the single retractor and the Y-loop at the rear of the seat, the harness30has several advantages. As mentioned above, the placement of the retractor902at a position low in the vehicle lowers the center of gravity, but at the same time the low mounting point reduces lockups of the retractor. However, this also assures that both shoulder harnesses lock together due to the Y-loop. This design also eliminates retractors normally positioned high and above the seat increasing rearward visibility for the passengers. Also by positioning the retractor in front of the seat, this allows a substantial length of the belt910(between the retractor and the Y-loop) allowing for significant variance in possible operator size and adjustability. Alternatively, the retractor902could be positioned under the seat.

With reference now toFIGS.50-52, the air intake system of the vehicle will be described. As shown best inFIG.50, an air intake system of the vehicle includes air intake84for cooling of the CVT52and an air intake system80as air intake to the engine. As shown, air intake system84includes an intake bezel984which can be directly coupled to the pillar portions440in a trapezoidal area986(seeFIG.27) of the pillar portion440, where aperture988allows air into the bezel984. Air is also drawn through louvers990and into bezel984. Air extends through bezel984and into duct992which is coupled directly to the CVT52for drawing air into the CVT52for cooling purposes.

In a similar manner, a bezel994is provided on the passenger side pillar portion440which couples to a duct996which is an intake to air filter998(FIG.52) which exits to duct1000having an outlet1002for intake to the engine. Air filter998is positioned directly behind the seats24,26such that the removal of a protective panel1004which provides easy access to the air filter998as shown best inFIG.52.

With reference now toFIGS.53and54, the packaging of the headlights relative to the radiator will be described. As shown inFIG.53, radiator46is coupled to the frame by way of a radiator frame1010having a box shaped enclosure at1012to encompass the radiator46and side arms at1014. A top bracket1016is provided coupled to U-shaped support116having a bracket1018conforming to a top of the radiator46. A headlight1020is positioned adjacent to the radiator where the light has a diagonally shaped body portion1022(FIG.54) and the electronics of the headlight defines a staggered or notched design having a rear body portion1024and1026defining a notched portion at1028. As shown, radiator46is positioned in the notched portion1028such that the rear portion1026and the remainder of the headlight1020extends rearwardly of the radiator46, such that a rearward most point of the headlight1020is rearward of a forward most point of the radiator46. This design maximizes the location of the radiator and resultantly, the approach angle at the front of the vehicle.

With reference now toFIGS.55-57, a shifter mechanism1030will be described in greater detail. As shown, shift mechanism1030generally includes a shift lever1032, gate1034, shift housing1036and actuator1038. As shown, shifter assembly1030is coupled between front and rear frame tubes152,154and intermediate seats24,26. With reference now toFIG.57, shift lever1032includes a shift handle1040coupled to a shift rod1042. Lever shaft1042includes a radiused portion1044including a bearing carrier at1046. A ball joint bearing1048is positioned within an inner diameter1050of bearing carrier1046and is held in place by snap ring1052. A spring retainer1054is provided having a lower cylindrical portion1056and an upper arm1058having a spring retaining aperture at1060. Shift rod1042also includes a lower flange at1064having a square opening at1066. In the embodiment shown, bearing1048is a ball joint bearing and spring retainer1054rotates with the shift lever1042. Finally, shift rod1042includes an eyelet at1070, and a spring1072is positioned between the eyelet1070and the aperture1060of spring retainer1050. Tension spring1072biases the shift lever towards the driver within the gate1034.

Shifter housing1036includes a lower flange at1076for mounting to front cross tube152and a rear flange1078for mounting to rear cross tube154. A gate support platform1080is provided which is flanked by upstanding walls1082having cylindrical supports1084which act as a trunnion for supporting shift lever assembly1032. Namely, a shaft1086extends through cylindrical members1084through bearing1048, through cylindrical portion1056of spring retainer1054. A snap ring1088which couples to a groove1090in shaft1086retains the shaft1086and the shift assembly1032to the cylindrical members1084. The actuator1038includes a front head1094having a square shouldered fastener at1096which cooperates with square opening1066and a fastener1098is coupled to threaded end1100to fix the actuator1038to the shift assembly1032.

With reference now toFIGS.58-61, the passenger grab bar32will be described in greater detail. With reference first toFIG.11, the frame includes a driver side bolster plate1110, and a passenger side bolster plate1112which couples a cross tube1114thereto. Bolster plate1112is a stamped component which allows a lightweight solution and a custom shape offering rigidity. Alternatively, bolster plate1112could be a casting. As shown inFIG.58, brackets1116are coupled to the cross tube1114and lower brackets1118are coupled to brackets1116. As shown inFIGS.59and60, brackets1118include a flange portion1122and a tubular receiver1124. Tubular receiver1124includes a slotted opening1126which extends to a front end of receiver1124(FIG.58). Receiver1124further includes lower flanges1128(FIG.60) which receive a rotary cam1130having an over center cam portion1132. A detent1134is provided in rotary cam1130which cooperates with detent opening1136. A sleeve1140is provided which is received in opening1138and has tab locks1142which cooperate with apertures1144of sleeve1124. Sleeve1140has an opening1146(FIG.61) at an underside thereof which receives the cam lock, as described further herein.

The grab handle1150of the assembly includes a U-shaped hand grip1152which may be covered with a grip portion, such as a thermos-plastic rubber or foam member, and two elongate attachment rods1154. As shown best inFIG.61, a lower side of attachment rods1154includes scalloped detents1156. A free end of each of the rods1154includes an opening1160(FIG.58) with an aperture1162(FIG.60) adjacent a free end of the rods1154. A leaf spring1164includes a guide tab1166positioned on one of the legs of the leaf spring1164and when positioned within opening1160of rod1154, guide tab1166protrudes through aperture1162, as best shown inFIG.58.

Thus, when rods1154are inserted through sleeve1140and into tube1124, the guide tab1166is positioned in the guide slot1126and when the rods1154are moved to the fully inserted position, guide tabs1166protrude beyond the slot1126, as shown inFIG.58. The grab bar1150however, may be moved to multiple other positions closer to the seat of passenger by rotating the cam locks1130downwardly, disengaging the rotary cam1132from the scalloped portions1156, and aligning a new scalloped portion1156with the rotary cam over center cam1132and moving the rotary cams1130back to the locked position shown inFIG.58.

As shown inFIG.62, steering assembly34is shown with steering wheel36. Steering assembly generally includes a power steering motor1170, a frame portion1172, a wiring housing1174, and a disengagement lever1176. Disengagement of the lever1176allows the frame1172to tilt up and down according to the arrow directions1178and1180. The steering wheel36is also longitudinally movable in the directions of arrow1182. Spring1184provides a biasing force in the position of arrow1178.

As shown inFIGS.63-66, the steering assembly has been modified to allow power to interface to the front of the steering wheel for such items as control features, yet allow the steering wheel to rotate, without the use of a clock spring. As shown best inFIG.63, the steering assembly34is shown with the wiring housing1174partially broken away to show the internal electrical cord1186. Housing1174includes a tubular portion1188and a plate portion1190. A cap1192is positioned over the plate portion1190. As shown inFIG.64, the cord1186has a portion1194extending from the housing1174and a portion1196which extends under the cap1192.

With reference now toFIGS.65and66, the cord portion1196will be described in greater detail. As shown, the cord1186extends through an opening1200defined at the intersection of the tubular portion1188and the plate portion1190. The cord portion1196extends around the steering column1202and is wrapped in the direction of arrow1204. The cord is wrapped to a position1196a, where it extends laterally at1196b, and then forms a portion1196which extends rearwardly and interfaces the front portion1210of the steering wheel36. In this way, a robust yet sealed connection is provided which improves over the clock-spring style connections used in prior vehicles. This design has proven effective in the environment intended for the vehicle described herein, where dust and dirt may be present.

With reference now toFIGS.67and68, a door assembly1220of the vehicle is shown, including a body portion1222and an inner frame portion1224(FIG.68). Body portion1222is generally V-shaped, including an upper leg1226and a lower leg1228defining an opening1230therethrough allowing escape of the air in the cabin to move outwardly and to create an air flow therethrough. Opening1231at the front end thereof also provides an area for air to escape from the cabin. Frame1224is hingedly coupled to the frame brackets224and226at a rear side of the door1220and is latched to the bolster plate1110. Thus, the door swings outwardly about hinges1232,1234but latches at the front end thereof.

With reference now toFIGS.69-72, an alternate steering assembly will be described which is an alternative to that which is shown inFIGS.62-66. Steering assembly1350is shown with steering wheel1352. Steering assembly1350generally includes a power steering motor1170(FIG.62), a frame portion1354, a wiring housing1356, and a disengagement lever1358. The steering wheel1352is also longitudinally movable in the directions of arrow1364. Springs1370provides a biasing force in the position of arrow1360.

As shown inFIGS.69-72, the steering assembly has been modified to allow power to interface to the front of the steering wheel1352for such items as control features, yet allow the steering wheel to rotate, without the use of a clock spring. As shown best inFIG.69, the steering assembly1350is shown with the wiring housing1356partially broken away to show the internal electrical cord1372. Housing1356includes a tubular portion1374in which the cord1372extends. A cap portion1376of the wiring housing1356is positioned adjacent to the steering wheel1352. As shown inFIGS.70and72, a cup portion1380is coupled to the backside of the steering wheel1352by way of fasteners1382. The cup portion1380includes a wiring outlet1384extending from a backside through to the frontside of the cup portion1380. As shown inFIGS.69and70, the cord1372has a portion1390extending from the housing1356and a portion1392which extends under the cap portion1376and then protrudes though the wiring outlet1384.

With reference now toFIG.72, the cord1372will be described in greater detail. As shown, the cord1372extends through the tubular portion1374and into the cap portion1376. The wiring housing1356includes an inner diameter wall1396which together with an inner diameter1398of cap portion1376, defines an annular opening1400. Thus when steering wheel1352turns, cup portion1380turns with the steering wheel1352and the cord1372is wrapped around the inner diameter wall1396and moves within the annular opening1400. The cord1372can expand and contract due to its coiled configuration and may be covered by a sleeve1402for sealing purposes. As the tubular portion1374is positioned along the side of the steering column, a gauge may be positioned on the cap portion and be movable therewith. Alternatively, the gauge may be positioned on the top of the steering column.

As shown best inFIGS.69and71, steering assembly1350includes a housing1410from which steering post1412extends. Steering post1412extends through the wiring housing1356, though the cup portion1380and through an opening1414of the steering wheel1352(FIG.70). A fastener1416couples with the threads1418(FIG.71) on the steering post1412. It should be understood that moving the lever1358allows the housing1410to rotate in the direction of arrows1360,1362(FIG.69) relative to frame portion1354. This also allows the steering post1412to move longitudinally relative to the remainder of the steering assembly. A decorative cover portion1420can be coupled to the steering wheel1352to cover fastener1416. In this way, a robust yet sealed connection is provided which improves over the clock-spring style connections used in prior vehicles. This design has proven effective in the environment intended for the vehicle described herein, where dust and dirt may be present. Also a gauge (seeFIG.3) can be mounted to an upper surface1422and tilt with the steering assembly1350but not telescope. This self adjusts the position of the gauge1424as the rider adjusts the tilt position of the steering assembly1350.

With reference now toFIGS.73-75, cab frame1425will be described in greater detail. As shown, cab frame1425generally includes frame tubes1430, cross tube1432, bracket assemblies1434, cross tube1436, bracket assemblies1438and pillar portions1440. As shown best inFIG.74, frame tubes1430are shown including a front portion1444having a coupler at1446, a central portion1448and a rear portion at1450, including a downwardly extending portion1451having couplers at1452. Each of the front1444, center1448, rear1450and downwardly extending1451sections are separated by an angled portion at1456,1458and1459.

Bracket assemblies1434includes flanges1470and1472, where each flange is coupled to a channel1476for receiving the cross tube1432. In a like manner, bracket assemblies1438includes flanges1478and1480, where each flange is coupled to a channel1482for receiving the cross tube1436. The cross tubes1432and1436include inserts1490coupled to ends of the tubes1343and1436, and are received in the channels as shown best inFIG.74. As shown best inFIG.75, inserts1490include apertures1494, for receiving fasteners1496, which couple to counter fasteners1498.

Pillar1440is shown best inFIG.74as including a front tube1500and a rear tube1502with connecting tubes1504,1506and1508. Lower couplings1510allow the cab frame1425to be coupled to the vehicle frame.

It should be appreciated from the above description that the frame tubes1430are continuous one-piece members with bends at1456,1458and1459. Also, the inserts1490could be a cast material such as a cast aluminum.

With reference now toFIGS.11and76-78, an alternate passenger grab bar1520will be described in greater detail. With reference first toFIG.11, the frame includes a driver side bolster plate1110, and a passenger side bolster plate1112which couples a cross tube1114thereto. Bolster plate1112is a stamped component which allows a lightweight solution and a custom shape offering rigidity. Alternatively, bolster plate1112could be a casting. As shown inFIGS.76and77, tubes1522are coupled to the cross tube1114and to lower brackets1523are coupled to tubes1522. As shown inFIG.77, brackets1523include a tubular receiver1524, where tubular receiver1524includes flanges1528(FIG.78) which receive a rotary cam1530having an over center cam portion1532. A sleeve1540is provided which is received in opening1538and has tab locks1542which cooperate with apertures1544of tubular receiver1524. Sleeve1540has an opening1546(FIG.78) at a side thereof which receives the cam lock1530, as described further herein.

A grab handle1550of the assembly includes a U-shaped hand grip1552which may be covered with a grip portion, such as thermos-plastic rubber or a foam member, and two elongate attachment rods1554. As shown best inFIG.78, an inside of attachment rods1554includes scalloped detents1556. A free end of each of the rods1554includes an aperture1562. A leaf spring1564includes a guide tab1566positioned on one of the legs of the leaf spring1564and when positioned within open end of rod1554, guide tab1566protrudes through aperture1562.

Thus, when rods1554are inserted through sleeve1540and into tubular receiver1524, the guide tab1566is positioned in a guide slot1570and when the rods1554are moved to the fully inserted position ofFIG.77, guide tabs1566protrude beyond the slot1570, as shown inFIG.77. The grab bar1550however, may be moved to multiple other positions closer to the seat of passenger by rotating the cam locks1530inwardly, disengaging the rotary cam1532from the scalloped portions1556, and aligning a new scalloped portion1556with the rotary cam over center portion1532and moving the rotary cams1530back to the locked position. It should be understood that the guide tabs1566are positioned in the guide slot1570only when the grab bar1550is in the full rearward position, closest to the passenger, and forms a stop so that the grab bar cannot be pulled out of the chassis.

With reference now toFIGS.79-80, an alternate removable front frame portion1620will be described in greater detail. As shown, removable front frame portion1620is similar to removable front frame portion320(FIG.20) with the exception that brackets1622for mounting the differential include slotted openings1624which allows the front final drive70to be suspended from the brackets1622. Removable portion1620also has frame tubes234having a coupler254which couples to the coupler330in a similar manner as described above.

With reference now toFIGS.81-82, a removable bearing assembly1670will now be described. As shown, removable bearing assembly1670is shown attached and spanning the longitudinal portions108. In this embodiment however, the recessed wall at1680has a window1682, which provides direct access to bearing386, whereas recessed wall380was solid (seeFIG.26). The removable bearing assembly1670is otherwise substantially identical to that shown and described in relation toFIGS.24-26.

With reference toFIGS.83-85, a cooling system of the vehicle will be shown and described. As shown, cooling system is shown as1700which is generally comprised of a radiator shroud1702, radiator1704and fan1706. As shown best inFIG.85, shroud1702is comprised of an upper wall at1710, side walls at1712and a lower wall at1714where wall1710-1714define an opening1716which provides access for cooling air against radiator1704. Side walls1712include flanges1720and1722for coupling with complimentary flanges1724and1726(FIG.84) respectively. Upper wall1710includes a defined pocket at1730which as shown inFIG.83, provides a mounting location for voltage regulators1732. Voltage regulators are mounted to a bracket (not shown) which overlies the pocket1730and locates the voltage regulators in the pocket1730in the position shown inFIG.83. As the shroud1702faces the front of the vehicle, air is moved into shroud1702across the radiator1704and through fan1706. As voltage regulators1732sit in the direction of air flow, the air flow also cools the voltage regulators.

A shown inFIGS.83and84, latches1734extend forwardly from fan housing1735and latch to radiator1704when in the position ofFIG.83. Shroud1702includes a notch1736for clearance which receives a leading edge of the latch1734as best shown inFIG.83.

With reference now toFIGS.86-99, an alternate seating adjustment mechanism will be described which is an alternative to that shown inFIGS.38-45. As shown, seating adjustment mechanism is shown as1740which allows the seat adjustment in both the for and at direction as well as the tilt direction. In the embodiment shown inFIG.86, the for and at adjustment is substantially the same as that shown inFIGS.38-45and will therefore not be described in further detail with respect toFIG.86. However, the tilt mechanism1734is somewhat different and will be described.

As shown best inFIG.91, seat adjustment mechanism1740includes longitudinally movable track systems1742which are substantially similar to that shown inFIG.43. The tilt mechanism1744includes inner frame members1780and outer frame members1782and in this configuration, allows only three discreet positions of tilt by way of apertures1784a,1784band1784c(FIG.91). A bracket1786is coupled to the top of the longitudinally movable track systems1742to which a fastener1788is fixed. Fastener1788is internally threaded and can be aligned with any of the apertures1784a,1784bor1784cby rotating the frame members1780and1782. Fasteners1800are therefore provided which can be positioned into any of the apertures1784a-1784cand be threadably engaged with fasteners1788to lock the frame members1780and1782in any one of the three tilt positions.

In this embodiment, a release mechanism1820is also provided coupled to the bottom of the seat24as shown best inFIG.92which is positioned intermediate the longitudinally movable track members1742. As will be described, release mechanism1820moves latches880rearwardly decoupling the latches880from locking rod894. As shown best inFIG.94, release mechanism1820is coupled to the bottom of the seat24whereby seat24includes a front boss1826and rear bosses1828where front boss1826includes a threaded opening1830and rear bosses1828include threaded openings1832. Release mechanism1820is coupled to the bottom of the seat24by way of a front fastener1834which couples to threaded opening1830and fasteners1836which couple to threaded openings1832.

With reference now toFIGS.95-97, release mechanism1820will be described in greater detail. As shown, release mechanism1820generally includes a tray portion1840, a release member1842, a link1844and an actuator1846. Tray portion1840includes a lower wall1850, front end wall1852, side walls1854and upright portions1856which extend from side walls1854. Front wall1852defines an arcuate ledge at1860, and upright portions1856define bearing portions1862. Release portion1842includes a lever portion1870extending forwardly from a shaft portion1872and leg portions1874extend downwardly from shaft portion1872. It should be appreciated that shaft portion1872cooperates with arcuate ledge1860and is rotatable therewith. Actuator1846includes a body portion1880having shaft portions1882extending outwardly therefrom and which are profiled to be rotatably received in bearing portions1862. Leg portions1886extend downwardly from body portion1880and have apertures1888extending therethrough. An actuator portion1890extends upwardly from body portion1880and extends transversely of body portion including a contact surface at1892.

Link portion1844includes a front coupling at1900having an aperture at1902. A rear coupling1906has an aperture at1908. A pin1910is receivable through apertures1912of arms1874and through aperture1902of coupling1900. A circlip1914is received in a groove1916of pin1910. A pin1920is receivable through apertures1888of actuator member1846and through apertures1908of link member1844where a circlip1924is receivable in a groove1926of pin1920.

With reference now toFIGS.98and99, when the lever portion1842is moved upwardly in the direction of arrow1930to the position shown inFIG.99, link1844is moved in the direction of arrow1932which causes a counter rotation of actuator1846in the rotation of arrow1934. This rotation causes contact surface1892to engage with latches880(FIG.92) and rotating them to release from rod894.

With reference now toFIGS.87,89and90, the movement of passenger seat26will be described in greater detail. With reference first toFIG.87, passenger seat26does not have a longitudinally movable track system such as1744as in the driver's seat. Rather, the passenger seat has two longitudinally positions for the seat26but they are fixed positions as described herein. Also, the seat26has the same tilt positions as the driver's seat24as described herein.

As shown inFIGS.89and90, the passenger seat does not include the longitudinal tubes156but rather has outer mounting rails1940and inner mounting rails1942. Outer mounting rails1940include two longitudinally spaced apart fasteners1944coupled to the outside of the rails1940and outer rails also include two longitudinally spaced apart set of apertures at1946including pairs of threaded openings at1946a,1946band1946c. Thus to position the passenger seat26in the seat frame150, the outer rail1782(FIG.87) has an aperture alignable with one of the fasteners1944(FIG.89) and includes a second aperture alignable with one of the apertures1946a,1946bor1946c.

With reference now toFIGS.100-105, an air intake system of the vehicle will be described. As shown best inFIGS.100and101, an air intake system of the vehicle includes air intake1950for cooling of the CVT52and an air intake system1952as air intake to the engine. As shown, air intake system1950includes an intake bezel1954which can be directly coupled to the pillar portion1440, where air is drawn through louvers1960,1960aand1962and into bezel1954. Air travels through bezel1954and into duct1958which is coupled directly to the CVT for drawing air into the CVT for cooling purposes. As shown best inFIG.101, bezel1954has an inner intake surface1960and an outer intake surface1962, for receiving air therein in the direction of the arrows1966and1968, respectively. Inner surface1960includes a portion1960a, that slants at least partially outward such that air is received in the bezel1954when the air moves in the direction of arrows1970.

In a similar manner, a bezel1980is provided on the passenger side pillar portion1440which couples to a duct1982which is an intake to air filter1984(FIG.101) which exits to duct1986having an outlet for intake to the engine. As shown inFIGS.103-105, air filter1984is positioned directly behind the seats24,26such that the removal of a protective panel1990which provides easy access to the air filter1984as shown best inFIG.104. As shown best inFIG.101, bezel1980has an inner intake surface1994and an outer intake surface1996, for receiving air therein in the direction of the arrows1998and2000. Inner surface1994includes a portion1994a, that slants at least partially outward such that air is received in the bezel1980when the air moves in the direction of arrows2002.

As shown inFIG.102, debris screens2006aand2006bcould be added to cover the inner surface portions1960aand1960b, while an outer debris screen2008could cover the outer surface1962.

As shown inFIGS.103-105, the removable panel is shown removed, accessing the air filter1984, when removable panel1990is positioned above a lower panel portion2010. Removable panel1990could have ¼ turn fasteners2012for easy removal and installation.

With reference now toFIGS.106-111, the construction of seats24,26will be described in greater detail. With reference first toFIG.106, driver seat24will be described, and it should be understood that passenger seat26is substantially identical to the construction of driver seat24. Driver seat24is comprised of a shell2020having individual pad portions attached thereto. Namely, a right shoulder blade portion2022, left shoulder blade portion2024, lumbar portion2026and seat bottom2028are coupled to the shell2020. A head rest2030is also positioned above the shoulder blade portions2022and2024. With reference now toFIG.108, shell portion2020includes left-hand clips2040and right-hand clips2042. More particularly, left-hand clips2040include clips2040a,2040b,2040cand2040d. At the same time, clips2042include clips2042a,2042b,2042cand2042d. Meanwhile, the backside of pad portion2024includes catches2050a-2050dwhere each of the catches engages with complimentary hooks2040a-2040drespectively.

With reference toFIG.109, shell portion2020includes catches2060aand2060bwhich couple with hooks2062aand2062brespectively to retain the lumbar portion2026within shell2020. As shown inFIG.110, shell portion2020includes a hook2070which receives a catch2072on the lower side of seat bottom2028.

With reference now toFIG.111, the construction of the left shoulder blade portion2024is shown and is illustrative to the possible construction of all of the pad portions2022-2030. As shown, an inner frame portion is shown at2090which carries the catches2050a-2050d. The frame portion2090could be a composite of plastic type materials with metallic catches2050a-2050dor could be comprised of materials such as aluminum. An outer shell portion2094is provided whereby windows2096are provided such that window2096aallows catch2050ato protrude therethrough, window2096ballows catch2050bto protrude therethrough, window2096callows catch2050cto protrude therethrough and window2096dallows catch2050dto protrude therethrough. Meanwhile, pad portion2098may be coupled to the combination of members2090,2094and provide the padding and/or cushion for seat24. Rivets2099may also be added to increase the retention of pad portions2022-2030.

With reference toFIG.112, a steering wheel2100is shown with modular control buttons2102for adding and control of aftermarket parts. The buttons2102are not pre-wired to the wheel, but all wires go through one cord.

With reference now toFIGS.113and114, the CVT52will be described. As shown, CVT52includes a CVT cover comprised of an inner cover2110and an outer cover2112. The inner cover has a plurality of bosses at2114and the outer cover2112has a plurality of bosses at2216. Fasteners2118couple the inner and outer covers2110,2112at each of the pairs of bosses2114,2116, as more fully described with reference toFIG.114. As shown inFIG.114, boss2114has a mounting face2120though which a threaded aperture2122extends. Boss2116has an inner cavity2128, an inner shoulder2130, a mounting face2132, an outer face2134and an aperture2136. Fastener2118has a head portion2140having an inner shoulder2142, a shank portion2144, a barb2146and a threaded portion2148. Barb2146has a leading edge2150and a rear shoulder2152.

Barb2146is profiled to be received into aperture2136and into cavity2128, but be retained in place once the barb2146gets beyond the aperture2136, as the outer diameter of the barb2146is greater than the inner diameter of the aperture2136. Thus, when the fastener is backed out (to the right as viewed inFIG.114) shoulder2152will abut the inner shoulder2130of boss2116. Furthermore, fastener is profiled such that it can be fully disengaged from the inner housing2110, and remain coupled with the outer housing. This is due to the profile of the fastener in that, from the fully engaged position (the position shown inFIG.114) the fastener can move a distance of X1, that is, the distance between the shoulder2152and the inner shoulder2130. The distance X1is greater than the distance (X2) that the fastener2118needs to travel to be unthreaded from the threaded aperture2122.

Thus, the design provides ease of maintenance as the fasteners2118always remain coupled to the outer housing2112, even when they are disconnected from the inner housing2110. When the outer cover2112needs to be reattached to the inner housing2110, each fastener2118is already aligned with the corresponding boss2116and aperture2122.

While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.