Abstract: A motorcycle frame including a base portion and a removable portion that both bear operating loads of the motorcycle. The removable portion and base portion are fastened together at a joint comprising a first end cap having a protrusion, a second end cap having a recess, and a fastener having a fastener axis and extending through the first and second end caps. The protrusion and the recess are characterized by angled walls oriented at an acute angle with respect to the fastener axis. The angled wall engagement of the end caps ensures that substantially all shear loads in the joint are born by the end caps and not by the fastener. The motorcycle footpeg position can be changed by replacing the removable portion with a second removable portion having footpeg mounting structure at a different location than the removable portion.

Abstract: An article of clothing includes a body portion and a limb portion (e.g. a sleeve or pant leg) coupled to the body portion. The limb portion includes an expandable portion and a zipper assembly configured such that the zipper may be adjusted to extend and retract the limb portion between a standard length, and an elongated length. Closing the zipper assembly adjusts the limb portion to the standard length, opening the zipper adjusts the limb portion to the elongated length. The elongated length is particularly well suited for use during activities where the wearer's arms or legs may be outstretched, such as motorcycling.

Abstract: An apparatus and method for lubricating an internal-combustion engine includes a shaft extending through a gearbox, a gear and a sliding sleeve coupled to rotate with the shaft and adapted to move axially along the shaft, a gearshift fork in mating engagement with the sliding sleeve and moveable parallel to the shaft, a rib in the gearbox adjacent the shaft, and a duct extending into the gearbox. The duct preferably directs a lubricant onto the gearshift fork and the sliding sleeve. Preferably, the rib directs the lubricant from the duct onto the gearshift fork and the sliding sleeve. In an alternative embodiment, at least some of the lubricant flung from the shaft, gear, and sliding sleeve contacts the rib and is directed onto the sliding sleeve and the gearshift fork. Further preferably, a projection extends from the rib to direct the lubricant onto the sliding sleeve and the gearshift fork.

Abstract: An coolant pump for an internal-combustion engine including a housing, a cover sealingly coupled to the housing, an impeller assembly located between the housing and the cover, the impeller assembly defining a longitudinal axis and being rotatable about the longitudinal axis; and a flange positioned between the housing and the cover adjacent the impeller assembly such that the flange and the cover define a first cavity, the flange and the housing define a second cavity, and the flange includes an opening fluidly connecting the first and second cavities, the flange being contoured to at least partially surround the impeller assembly. Preferably, the pump also includes a nozzle contoured to direct a coolant from the first cavity toward the second cavity and onto the impeller assembly, and wherein the nozzle has an intake side communicating with the first cavity and a discharge side communicating with the second cavity.

Abstract: A motorcycle including a two-cylinder engine. The engine includes a housing, first and second cylinders having first and second combustion chambers, respectively, and first and second pistons reciprocating in the first and second chambers, respectively. The motorcycle further includes a spark generating circuit including a spark plug having a spark gap exposed to the first combustion chamber, an ion sensing circuit including the spark plug and being operable to generate an ion signal indicative of an ion current generated across the spark gap, and an analysis module coupled to the ion signal circuit. The analysis module is operable to receive the ion signal and to analyze the ion signal to determine whether a no-combustion event occurs in the first cylinder. The analysis module may be further operable to determine if the spark generating circuit has an intermittent connection.

Abstract: An apparatus and method for lubricating an internal-combustion engine includes a shaft extending through a gearbox, a gear and a sliding sleeve coupled to rotate with the shaft and adapted to move axially along the shaft, a gearshift fork in mating engagement with the sliding sleeve and moveable parallel to the shaft, a rib in the gearbox adjacent the shaft, and a duct extending into the gearbox. The duct preferably directs a lubricant onto the gearshift fork and the sliding sleeve. Preferably, the rib directs the lubricant from the duct onto the gearshift fork and the sliding sleeve. In an alternative embodiment, at least some of the lubricant flung from the shaft, gear, and sliding sleeve contacts the rib and is directed onto the sliding sleeve and the gearshift fork. Further preferably, a projection extends from the rib to direct the lubricant onto the sliding sleeve and the gearshift fork.

Abstract: A motorcycle engine capable of being supported within a frame. The engine includes a cylinder head having an upper peripheral edge and a valve cover having an assembled width and a lower peripheral edge substantially corresponding in shape to the upper peripheral edge of the cylinder head. The valve cover includes first and second portions coupled together along an engagement surface that does not extend across the entire assembled width of the valve cover. The second portion is separable from the first portion along the engagement surface to facilitate removal of the first portion from the engine. In one aspect of the invention, the first and second portions are separate castings.

Abstract: An apparatus for cleaning a spraying end of a paint sprayer includes a solvent vessel having an opening and containing a solvent. The opening is configured to receive the spraying end of the paint sprayer. A rotatable brush is only partially submerged in the solvent such that the spraying end contacts the brush when inserted into the opening. A motor is interconnected with and provides rotation to the brush. A signal generator is operable to provide an actuation signal that activates the motor such that the brush rotates and cleans paint from the spraying end of the paint gun.

Abstract: A system for determining engine phase in a motorcycle engine includes a crank gear sensor mounted near the crank gear of the engine, a pressure sensor mounted on the air intake manifold of the engine, and a processor communicating with the crank gear sensor and the pressure sensor. First and second groups of crank gear teeth pass by the crank gear sensor before either of the first and second pistons of the engine reaches TDC. At low rpm, such as at start up, the processor determines the phase of the engine during a single rotation of the crankshaft by measuring and comparing the time periods taken by the groups of teeth to pass by the crank gear sensor. At high rpm, the processor determines the phase of the engine using the pressure sensor.

Abstract: A motorcycle comprising a frame having left and right tail supports extending rearward, front and rear wheels coupled to the frame, and a rear fender positioned over the rear wheel and between the tail supports. The rear fender includes left and right flanges positioned adjacent inner surfaces of the left and right tail supports, respectively. In order to provide additional support to the fender, the motorcycle can further include an inner support coupled to an inner surface of the fender. Preferably, the inner support and the fender define a wire path in which wires from a taillight can be routed, thereby protecting the wires. The wire path can be continued by another wire path defined between the fender and a rear housing that has an overlapping portion coupled to the fender.

Abstract: The invention relates to an internal-combustion engine, in particular for a motorcycle. The motorcycle engine preferably includes a crankshaft rotatable about an axis, a web coupled to the crankshaft, and curved wall portions surrounding the crankshaft. The web has an outer surface which defines a substantially circular pathway as it rotates about the axis. Oil is preferably flung from the web and the crankshaft into an oil channel which has a longitudinal axis that is substantially tangential to an adjacent portion of the pathway. Additionally, oil which is flung from the web and the crankshaft onto the curved wall portions drains into the oil channel, which leads to an oil-storage tank. Preferably, the housing also includes a balancing shaft with a balancing web rotatable about a second axis, additional curved wall portions surrounding the balancing shaft and the balancing web, and a second oil channel. The balancing web has a balancing web outer surface that rotates along a substantially circular pathway.

Abstract: A system for determining engine phase in a motorcycle engine includes a crank gear sensor mounted near the crank gear of the engine, a pressure sensor mounted on the air intake manifold of the engine, and a processor communicating with the crank gear sensor and the pressure sensor. First and second groups of crank gear teeth pass by the crank gear sensor before either of the first and second pistons of the engine reaches TDC. At low rpm, such as at start up, the processor determines the phase of the engine during a single rotation of the crankshaft by measuring and comparing the time periods taken by the groups of teeth to pass by the crank gear sensor. At high rpm, the processor determines the phase of the engine using the pressure sensor.

Abstract: A fuel supply device is mounted to a motorcycle engine between two substantially identical air intake connections. The air intake connections each include a body portion with a projection and a flange, each extending radially from the body portion. Fasteners inserted through apertures in the flanges hold the air intake connections to the engine. The protrusion is preferably made of a resilient material, such as rubber. The flange is preferably made of a non-resilient material, such as aluminum. An aperture having an annular recess extends through the projection. The aperture is adapted to receive an internally threaded metal sleeve having an annular protrusion that surrounds the metal sleeve. A threaded fastener preferably extends through the metal sleeve and couples the fuel supply device to the projection. In the event that the fastener is excessively torqued during tightening the metal sleeve can spin in the aperture without damaging the projection.

Abstract: A saddlebag support assembly for use on a motorcycle includes a mounting member mounted to the motorcycle's shock bolt. A portion of the mounting member extends below a lower edge of the motorcycle's rear fender. The saddlebag support assembly also includes front and rear arms having front and rear plates. The front plate is mounted to the portion of the mounting member below the lower edge of the rear fender. An internal support member is mounted to the shock bolt and extends rearwardly thereof. The internal support member includes a depending portion defining a slot that receives the rear plate. The rear plate is fastened to the depending portion of the internal support member. The saddlebag support assembly further includes a bottom support for supporting the saddlebag from underneath, and a bracket having quick-release bosses. Quick-release fasteners are used to secure the saddlebag to the quick-release bosses from the inside of the saddlebag.

Abstract: A method and apparatus for determining the balanced condition of an engine having a balancer is provided. An engine balancer tester includes a sensor coupled to the engine. The engine generates first- and second-order vibrations that have vibration levels and the sensor generates a signal corresponding to the vibrations. A meter coupled to the sensor receives the signal and calculates a ratio between the vibration level of the first-order vibrations and the vibration level of the second-order vibrations. A comparator compares the ratio to a predetermined value to assess the balanced condition of the engine.

Abstract: A windshield assembly for use on a motorcycle includes a lower windshield mount fastened to the triple tree of the motorcycle. A windshield is pivotally mounted to lower windshield mount. A break-away mechanism is mounted to an upper portion of the windshield and releasably couples the windshield to an arm that is directly coupled to the handlebars of the motorcycle. If a predetermined force is applied to the windshield the break-away mechanism will release the windshield from the arm allowing the windshield to pivot.