Abstract: A saddlebag mounting system for use with a motorcycle that includes a frame having a mounting location for coupling a footpeg to the motorcycle. The saddlebag mounting system includes a first bracket configured to securely attach the mounting location, a second bracket removably coupled to the first bracket, and a saddlebag coupled to the second bracket such that uncoupling the second bracket from the first bracket disconnects the saddlebag and the second bracket from the motorcycle and leaves the first bracket attached to the frame.

Abstract: An ignition and key switch assembly for a motorcycle includes a cover having a front surface, a rear surface, a first cover portion and a second cover portion, an ignition coil located in the first cover portion, the ignition coil being held in the first cover portion by a protective layer, and a key switch received within the second cover portion and being accessible at the cover front surface. A mounting bracket is provided for mounting the cover to the key switch and an aligning feature is provided for aligning the cover to the key switch.

Abstract: A motorcycle includes a steering head, a steering assembly pivotably coupled to the steering head, at least one longitudinal frame member extending rearwardly from the steering head, and a rear frame member coupled to the longitudinal frame member. The rear frame member includes a mounting portion having a mounting surface, and first and second walls extending from the mounting surface at an oblique angle to the mounting surface. The motorcycle also includes a support coupled to the rear frame member. The support includes a coupling portion having a coupling surface, and first and second walls extending from the coupling surface at an oblique angle to the coupling surface. The first and second walls of the mounting portion are wedged against the first and second walls of the coupling portion, respectively, to substantially prevent rotation of the support with respect to the rear frame member.

Abstract: A handlebar assembly for a motorcycle includes a riser and a cap coupled to the riser. The cap and riser define a clamp having a cavity. The handlebar assembly also includes a handlebar having a first end portion and a second end portion opposite the first end portion. The second end portion is configured to support a hand grip. The first end portion defines an axis and is at least partially received within the cavity. At least one of the clamp and the first end portion includes an axial locking feature to inhibit movement of the handlebar relative to the clamp in a direction along the axis. The axial locking feature permits rotation of the handlebar assembly about the axis to adjust the position of the second end portion.

Abstract: A seat assembly for a motorcycle includes a rider seat having a forward end and a rearward end, a mounting bracket pivotally coupling the forward end of the rider seat to a frame of a motorcycle, the rider seat being pivotable to raise the rearward end of the seat, and a support arm. The seat assembly further includes a rear seat support having a first end portion and a second end portion, the first end portion being pivotally coupled to the support arm and the second end portion supporting a rear seat. The rear seat support is pivotal from a first position in which the rear seat is hidden from view below the rider seat to a second position in which the rear seat can support a passenger. The seat assembly also includes a stop feature for supporting the second end portion relative to the support arm and a lock feature for inhibiting pivoting of the rear seat support.

Abstract: A luggage rack and passenger seat combination for a motorcycle includes a luggage rack assembly configured to mount to the motorcycle. The luggage rack assembly has a support member operable to support cargo on a support surface thereof, the luggage rack assembly including a first engaging feature and a second engaging feature. A passenger seat assembly includes a movable mounting member and a fixed mounting member. The movable mounting member is movable between an unlocked position and a locked position. The movable mounting member is engageable with the first engaging feature and the fixed mounting member is engageable with the second engaging feature to removably couple the passenger seat assembly to the luggage rack assembly to support a passenger of the motorcycle.

Abstract: An exhaust system for a motorcycle engine including a header having an upstream end adjacent a combustion chamber of the engine and having a downstream end opposite the upstream end. The exhaust system includes a catalytic converter positioned downstream of the combustion chamber and configured to improve the emissions quality of exhaust gases discharged from the combustion chamber. The exhaust system further includes a perforated section at least partially defining an exhaust passageway, the perforated section disposed adjacent the downstream end of the header. A resonator chamber is in fluid communication with the perforated section. The resonator chamber is configured to allow expansion of the exhaust gases in the exhaust passageway through the perforated section.

Abstract: A rocker box assembly for a motorcycle engine having a cylinder head. The rocker box assembly includes a base, a cover, and a breather assembly. The base is configured to be coupled to the cylinder head. The cover is coupled to the base and cooperates with the base to at least partially define a rocker chamber and to at least partially define a breather assembly housing within the rocker chamber. The breather assembly is positioned within the breather assembly housing and is operable to vent a pressure pulse from within the engine.

Abstract: A tail light assembly for a motorcycle includes a first array of at least one LED in illuminated in at least a first color. The first group of LEDs operates in a non-operating condition, a running condition where each LED of the first array is illuminated at first intensity, and a braking condition where each LED is illuminated at a second, brighter intensity. A second array of at least one LED is illuminated in at least a second color. The second array operates in a non-operating condition, and a flashing condition where each LED of the second array alternates between being illuminated and not illuminated. Each LED of the first array is illuminated at the first or the second intensity while each LED of the second array alternates between being illuminated and not illuminated in the flashing condition.

Abstract: The present invention provides a motorcycle including a front wheel, a rear wheel, a frame supported by the front and rear wheels, a crankcase including a first interface portion and a first passageway exposed to the first interface portion, a reservoir located remotely from the crankcase adapted to contain a lubricant, and a transmission case supported by the frame and including a second interface portion and a second passageway exposed to the second interface portion. The second passageway is in fluid communication with the reservoir. The first interface portion is coupled to the second interface portion. The first passageway is in fluid communication with the second passageway. The first and second passageways provide fluid communication between the reservoir and the crankcase through the first and second interface portions.

Abstract: A motorcycle including a frame, an engine mounted to the frame, and a stand movable between an extended position in which the stand supports the motorcycle and a retracted position. The motorcycle includes a sensor operable to generate a stand signal indicative of at least one of the extended and retracted positions of the side stand and a controller electrically coupled to the sensor to receive the stand signal. The controller is programmed for preventing operation of the engine based on the stand signal during a first operating condition of the motorcycle and is further programmed to allow running of the engine during a second operating condition of the motorcycle, regardless of the stand signal.

Abstract: A primary locking tool for use with first and second primary drive assemblies. The first primary drive assembly includes a first drive sprocket and a first input sprocket a first distance from one another. The second primary drive assembly includes a second drive sprocket and a second input sprocket a second distance from one another. The second distance is greater than the first distance. The primary locking tool includes a first side portion having a drive jaw configured to engage the first and second drive sprockets. A second side portion includes an input jaw configured to engage the first and second input sprockets. The first and second side portions are coupled together for movement between a retracted position and an extended position that engage and resist rotation of the first drive sprocket and first input sprocket and the second drive sprocket and second input sprocket, respectively.

Abstract: The present invention provides an air intake assembly including a first portion defining a first chamber through which airflow passes. The first portion is coupled to a first throttle member to allow communication from the first chamber to the first throttle member. The air intake assembly also includes a first filter element coupled to the first portion and positioned upstream of the first chamber, and a second portion defining a second chamber through which airflow passes. The second portion is coupled to a second throttle member to allow communication from the second chamber to the second throttle member. The air intake assembly further includes a second filter element coupled to the second portion and positioned upstream of the second chamber, and a conduit coupling the first and second portions. The conduit allows communication between the first and second chambers at a location downstream of the first and second filter elements.

Abstract: A muffler for a motorcycle, the muffler including an outer tube and an inner tube disposed substantially within the outer tube. The inner tube includes a first end adapted to receive the exhaust gases from the engine, a second end opposite the first end adapted to release the exhaust gases to the environment, and first and second apertures positioned between the ends. The muffler also includes a mesh tube disposed between the outer tube and the inner tube. The mesh tube defines a chamber between the inner tube and the mesh tube such that the exhaust gases exit the inner tube through the first aperture into the chamber, and exit the chamber into the inner tube through the second aperture. The muffler also includes a noise attenuating material disposed between the mesh tube and the outer tube.

Abstract: The invention provides a motorcycle having a frame, an engine coupled to the frame, and a crankshaft assembly. The crankshaft assembly includes a first flywheel half having an aperture, a crank pin including a first end portion, a second end portion opposite the first end portion, and a bearing surface between the first and second end portions. The first end portion is press-fit into the aperture of the first flywheel half. The first end portion, the second end portion, and the bearing surface are coated with a friction enhancer. A bearing is positioned at least partially onto the bearing surface, and a connecting rod has an aperture that at least partially receives the bearing.

Abstract: An intake system for a motorcycle having an engine. The intake system includes an air box having a first opening for receiving intake air and a second opening for supplying the intake air from the air box to a throttle assembly of the engine. A filter element is disposed within the air box for separating debris from the intake air. A valve is disposed within the air box between the filter element and the second opening. The valve is movable to provide a variable restriction to intake air flow through the air box.

Abstract: The invention recites an exhaust pipe clamp for clamping at least two pipes. The clamp includes a band formed to at least partially surround each of the two pipes, the band defining an internal volume. A reaction block is interconnected with the band and disposed substantially within the internal volume. The exhaust clamp also includes a clamping member operable to reduce the internal volume of the band.

Abstract: A primary housing for a motorcycle engine includes an inner housing that defines internal coupling apertures, transmission coupling apertures, and external coupling apertures. Internal fasteners extend through the internal coupling apertures and the transmission coupling apertures to couple the inner housing to the crankcase and the transmission. An outer housing defines coupling apertures that align with the external coupling apertures and fasteners extend through the coupling apertures, through the external coupling apertures, and into the engine crankcase to couple the inner and outer housings to the crankcase. A resonant damping device is rigidly or moveably coupled to an anti-node region of the outer housing to reduce noise emissions from the outer housing during engine operation.