Abstract: An air intake system includes an air cleaner for housing an air filter element therein above an off road vehicle engine, and a surge tank, which buffers the filtered air, at a location beside the engine. A descending tube from the air cleaner connects into a top cover of the surge tank, and an outlet tube of the air intake system extends horizontally from the top cover of the surge tank for connection into the throttle of the engine. A vapor recovery pipe connect the crankcase of the engine, lower than the outlet tube, back up to the air cleaner upstream of the filter element. The surge tank includes a tank bottom casing removably connected to a tank upper cover, with the descending tube and the outlet tube connecting into the tank upper cover.

Abstract: A swing arm type suspension for a rear wheel of an off road vehicle can use two or three tie rods to control toe-in of the knuckle. The rear end of the swing arm is split between an upper clamping arm and a lower clamping arm defining an eye, with the knuckle connected to the upper and lower clamping arms by joint bearings, and with either the transmission shaft or one of the tie rods extending through the eye of the swing arm to the knuckle. The front of the swing arm can be connected to the vehicle frame using a cross-shaft joint. Camber, toe-in and half-track width are controlled to result in a smaller turning radius with better ride characteristics.

Abstract: A type of constant velocity universal joint has the spline slip structure, including the steel wire retaining ring and the star-shaped sleeve which are both mounted on a common axis, and the steel wire retaining ring limiting device. The said steel wire retaining ring limiting device is a groove arranged on the said star-shaped sleeve and used for holding the said steel wire retaining ring. The said steel wire retaining ring may be elliptic or circular. The movement in the radial direction of the steel wire retaining ring will be limited by the groove on the star shaped sleeve and there occurs a certain contraction, in addition to appropriate the chamfer angle of the groove, when removing the spline shaft from the star-shaped sleeve.

Abstract: A quick disassembly tool for fixedly mounting a connection module is provided according to the present application, including a pressing block and a fixing block for press-fitting the connection module. A press-fitting end face of the fixing block is provided with a press-fitting hole, and a press-fitting post inserted into the press-fitting hole protrudes from the pressing block; the quick disassembly tool further includes a locking device respectively pressing on an end of the pressing block and an end of the fixing block, and the locking device includes an elastic pressing device configured to adjust a press-fitting space between the pressing block and the fixing block. The pressing block and the fixing block are connected and transversely position-limited through the press-fitting hole and the press-fitting post, the locking of the pressing block and the fixing block in a pressing direction is achieved by a locking device.

Abstract: An off road vehicle has an air heater with right and left shells surrounding and supporting a core, with the right and left shells connected by screws extending through ears on one of the shells into bosses on the other shell. Dual air control plates are mounted in the shell on a shaft for pivoting movement. An actuator is linked to the shaft by a swing arm with a guide pin riding in an arced slot of a drive plate rotationally secured to the shaft. The right and left shells are secured to the vehicle using a resilient compressible grommet, with a bushing extending through the grommet and a bolt extending through the bushing and attached into the frame.

Abstract: A mechanical locking differential includes a driving ring in a differential housing between right and left active components. The driving ring is in line with the input bevel gear. The differential housing has a thin wall in a single, integral shell around the driving ring. Several hollow cylindrical shaft pins are used to attached the driving ring to the differential housing, with the shaft pins being driven radially relative to the transverse axis of the differential outputs in an interference fit with the housing and the driving ring. The shaft pins are held from axially backing out by two small rivets. The shaft pins preferably have a threaded inner diameter which assists in removal. The shaft pin attachment allows the bevel gear to extend closer to the transverse axis without obstruction.

Abstract: A frame for an off road vehicle includes main beams establishing a base plane. Mounting beams, which can be used to support forces from the swing arm of a rear suspension, are spaced outside the main beams and within the base plane, running longitudinally in line with the swing arms of the rear suspension. Right and left longitudinal beams start within the base plane, but rise to their trailing ends so as to not interfere with the suspension travel of the swing arms as they extend back inward over the swing arms. Front and rear support columns can further attach into, secure and support the mounting beams and the longitudinal beams. All of the beams and columns can be formed by cutting cylindrical tubing to length and then curving the cylindrical tubing, each piece within a single plane.

Abstract: A mechanical locking differential includes a drive lock motor supported by the differential housing. The drive lock motor is disposed opposite the input bevel gear assembly, higher than the differential input and the differential outputs. The drive lock motor is coupled to a differential lock with a gear train that includes a worm drive, to output rotational motion on a lock output gear. The lock output gear causes sliding motion of a rack and a rack follower, pressing the differential lock into or out of engagement. The drive lock motor assembly is disposed fully between the right and left extents of the differential.

Abstract: A hydraulic control valve for an ATV or motorcycle takes hydraulic input from a hand brake lever as an input to a first cavity of the control valve with a movable piston therein, and from a foot brake lever as an input to a second cavity of the control valve with a movable piston therein, with the two pistons being linked. A bypass channel extends around the piston in the first cavity, which is closed off when the first piston moves longitudinally. The output of the first cavity hydraulically controls braking of the front wheel(s). The foot brake lever also pressurizes a direct line to brake the rear wheel(s) that doesn't go through the control valve.

Abstract: A mechanical locking differential primarily includes a drive ring and right and left driven rings that can move sideways into and out of engagement with the drive ring. The drive ring and the driven rings have teeth with an inverted trapezoidal shape with a significant clearance, such as a pressure angle of ?1° and a clearance of 20% circumferentially. A central ramping separator ring provides a ramping mechanism with inclines that push the driven rings out of engagement with the drive ring when the associated half axle rotates faster than the drive ring, with the ramping action occurring within the teeth clearance.

Abstract: The invention provides a type of all-terrain vehicle seat installation structure; it includes the cab frame and the seat backrest arranged on the frame; the back mounting side of the seat backrest includes the first mounting part and the second mounting part arranged up and down respectively. The first mounting part includes the upper support frame located at the upper end of the frame; the installation hole is arranged on the upper support frame; the installation pin inserted into the installation hole is extended out of the seat backrest. The second mounting part includes the lower support frame located at the lower end of the frame; the lower end of the seat backrest is provided with the installation buckle mounted on the lower support frame.

Abstract: An exhaust system for an off road vehicle includes a main intake pipe running in a generally longitudinal direction on the vehicle, receiving gasses from a first intake pipe for a forward cylinder and from a second intake pipe for a rearward cylinder of an mid-mounted internal combustion engine. A catalytic converter receives gasses from the main intake pipe. Instead of being mounted longitudinally, the catalytic converter extends in a transverse direction, at the rearward end of the exhaust system, behind the axis of the rear wheels. A muffler, located over the axis of the rear wheels, also extends in a transverse direction and receives gasses from the catalytic converter. The muffler outputs the gasses through a tailpipe, which is preferably above and extends wider than the main intake pipe.

Abstract: The invention discloses a type of seat, including the seat baseplate, the soft cushion and the underframe assembly; wherein, the said soft cushion is arranged on the said seat baseplate; the said seat baseplate is connected to the framework through the said underframe assembly; the said seat baseplate adopts integrated injection molding. The seat baseplate in the present invention adopts integrated injection molding. The soft cushion is arranged on the seat baseplate to form the complete seat. Compared with the machining method in the prior art that the backrest and the base are separately machined and then the backrest and the base are assembled with each other; the machining procedure of the seat baseplate in the present invention is simple, thus the production efficiency is improved and the production cost is reduced. The invention also discloses a type of all-terrain vehicle provided with the above seat.

Abstract: A swing arm type suspension for a rear wheel of an off road vehicle can use two or three tie rods to control toe-in of the knuckle. The rear end of the swing arm is split between an upper clamping arm and a lower clamping arm defining an eye, with the knuckle connected to the upper and lower clamping arms by joint bearings, and with either the transmission shaft or one of the tie rods extending through the eye of the swing arm to the knuckle. The front of the swing arm can be connected to the vehicle frame using a cross-shaft joint. Camber, toe-in and half-track width are controlled to result in a smaller turning radius with better ride characteristics.

Abstract: A mounting clip having two clip portions holds a windshield to a tube of a ROPS tube of an off-road vehicle. One of the clip portions includes an arm extending in a cantilevered fashion away from the windshield contact surface, curving partially around the tube but not encircling the tube. One of the clip portions includes deflectable tabs, extending through a windshield aperture and mating into recesses on the other clip portion, so the clip can be buckled by hand pressing the two clip portions together. The windshield and the arm pinch opposing sides of the tube, compressing a seal on the edge of the windshield.

Abstract: A half shaft connects to the mounting bracket of the wheel in a splined connection. The straight external spline of the half shaft is modified to a helical or involute external spline, in which the helix angle adopted is small. The mounting bracket of the wheel can be longitudinally advanced by hand assembly only part way onto the half shaft. The rest of the longitudinal advancement during assembly occurs by tightening the nut to completely eliminate the fit clearance between the external spline and its corresponding mating arrangement. Various road tests of vehicles verify that, when using the present invention, the nut does not loosen during use of the vehicle. The invention enables the locking force of the nut to be reduced, and assembly and maintenance are convenient.

Abstract: A drive shaft is formed by welding two spline shaft heads to a hollow middle section of tubing. The spline shaft head includes teeth which are crowned to permit an angular offset of the drive shaft relative to cylindrical splines of connectors, such that the end faces of the teeth define a barrel shape. The teeth of the spline shaft head include a side face curvature, defining a football-shaped tooth cross-section. Torque is rotationally transmitted across a permitted angular offset of the drive shaft relative to cylindrically arranged linear splines of drive and driven connectors (i.e., relative to the engine output axis of rotation and the differential input axis of rotation), thereby avoiding the use of prior art universal joints.