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: 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: This invention relates to a chain guide rail for an internal-combustion engine, having a body portion and a pin, both made with a first material, an overmolding of a second material which covers both the pin and the body portion, and a longitudinal axis through the length of the guide rail. The pin, inserted into a housing recess in the internal-combustion engine, is restrained from moving perpendicular to the first longitudinal axis but is free to move parallel to the axis. Preferred embodiments of the present invention utilize a fastener to hold the guide rail to the housing. Preferred embodiments also utilize raised portions spaced along the guide rail which reduce the longitudinal shrinkage during cooling of the second material.

Abstract: An automatic decompression device for an internal combustion engine includes a camshaft rotatable about an axis of rotation and having an end face, and a lever coupled to the end face and movable between a first position, wherein the lever is engageable with a valve actuating device to actuate a valve during rotation of the camshaft, and a second position, wherein the lever does not substantially move the valve actuating device. The lever is preferably pivotally coupled to the end face to pivot about a pivot axis that is substantially perpendicular to the axis of rotation of the camshaft. Further preferably, the automatic decompression device further includes a spring between the end face and the lever to bias the lever toward the first position. In a highly preferred embodiment, the end face of the camshaft includes a slot and the lever is at least partially retained within the slot.

Abstract: This lubricating device for a wet multi-disk clutch, which is suitable particularly for use in internal combustion engines of motorcycles, comprises several disks, which are combined into a disk package between an outer hub and an inner hub and surround the outside of a jacket part of the inner hub and, over openings of the lubricating device in the jacket part, are supplied with lubricating oil from a drive shaft having a borehole. To achieve optimum lubrication of the disks, the inside of the jacket part, which is provided with openings, is provided, as seen in the axial direction of the jacket part, with a bevel, which extends from a bottom to a free end of the inner hub, which has a radial oil-damming web and is adjacent to the free end.

Abstract: The invention relates to an internal-combustion engine, in particular for motorcycles, with a crankshaft (24) which is arranged in a crankcase (10, 14) and which is connected by way of connecting rods (20, 22) to pistons arranged so as to be movable in cylinders (16, 18), with an oil sump (12) which is situated below the crankcase (10) and from which the lubricating oil is conveyed to the consumer devices by way of an oil pump (60), and with means for returning the lubricating oil from the consumer devices to the oil sump (12). It is proposed that, in order to separate the oil taken up in particular by the crankshaft (24), a part of the crankcase (10) adjacent to the crankshaft (24) has a wall portion (26a to d) which extends parallel to the axis of rotation of the crankshaft (24) and the outline of which is adapted to the enveloping curves of the crankshaft webs (27, 28) and/or the connecting rods (20, 22). A rapid return of the lubricating oil to the oil sump is made possible by this step.

Abstract: A motorcycle that includes a luggage rack and/or backrest secured to a mounting bracket. The mounting bracket is positioned under the motorcycle seat and is secured to the rear fender of the motorcycle. Attaching the mounting bracket below the motorcycle seat conceals the mounting hardware that is used to secure the mounting bracket to the rear fender. Concealing mounting hardware on a motorcycle enhances the aesthetic appearance of the motorcycle.

Abstract: A motorcycle having a system for combustion knock control. The motorcycle includes a spark generating circuit having a spark plug. The spark generating circuit produces a spark across a spark gap of the spark plug in response to a sparking signal. The motorcycle further includes an ion signal circuit that provides an ion signal indicative of an ion current being generated across the spark gap, and an analysis module electrically connected to the ion signal circuit and the spark generating circuit. The analysis module generates the sparking signal in a timed sequence, receives the ion signal from the ion signal generating circuit, measures a knock intensity within the ion signal, and modifies the timing sequence when knock is present.

Abstract: A saddlebag mounting system that eliminates the need for external fasteners on the rear fender and corresponding tail section. The saddlebag is mounted to the inner surface of the rear fender using a saddlebag mounting system, including a mounting bracket. The mounting bracket preferably includes an inner bracket coupled to the inner surface of the rear fender, and an outer bracket coupled to the inner bracket, the saddlebag being mounted to the outer bracket. The rear fender can be provided with an inner support mounted to the inner surface to facilitate attachment of the inner bracket. For example, the inner support can include a slotted opening, and a fastener can be used to couple the inner bracket to the inner support.

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 mounting system that eliminates the need for external fasteners on the rear fender and corresponding tail section. The saddlebag is mounted to the inner surface of the rear fender using a saddlebag mounting system, including a mounting bracket. The mounting bracket preferably includes an inner bracket coupled to the inner surface of the rear fender, and an outer bracket coupled to the inner bracket, the saddlebag being mounted to the outer bracket. The rear fender can be provided with an inner support mounted to the inner surface to facilitate attachment of the inner bracket. For example, the inner support can include a slotted opening, and a fastener can be used to couple the inner bracket to the inner support. Preferably, the fastener includes a head portion positioned within the slotted opening.

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 cylinder head for a motorcycle engine includes a lower surface adapted to be coupled to a cylinder, an upper surface adapted to be coupled to a rocker box and defining a plane, and a side connected between the upper surface and the lower surface. The head also includes a breather inlet extending into the upper surface, an intermediate passage extending into the upper surface, and a breather channel connecting the inlet and the intermediate passage, the breather channel lying in a plane that is generally parallel to the plane of the upper surface. The head also includes a breather passage extending into the side of the head and connected to the intermediate passage, the breather passage having a longitudinal axis that is generally parallel to the plane of the upper surface.

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: 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: A motorcycle includes a frame having an upper member, a pair of front members, a pair of lower members, and a pair of rear members. An engine is mounted to the frame with a pair of bolts, one of which is disposed adjacent the front members of the frame, and the other of which is disposed adjacent the lower members of the frame. The rear portion of the engine is mounted to the motorcycle transmission assembly along a vertical interface. The transmission assembly is mounted to a cross member joining the lower members of the frame, to the upper member of the frame with an upper support, and to the rear members of the frame with a swing arm bolt.

Abstract: A motorcycle wheel includes a rim portion, a hub portion, a joining portion extending between the hub portion and the rim portion, and an axle housing portion. The joining portion includes first and second sidewalls defining outwardly-facing continuous concave surfaces. The first and second sidewalls define a well adjacent the rim portion. The first and second sidewalls contact each other at a merger portion intermediate the hub portion and the rim portion. The first sidewall is slightly thicker than said second sidewall to facilitate casting the wheel as one piece. A merger point in the merger portion has a thickness that is less than the minimum thicknesses of a portion of the first and second walls between the hub portion and the merger portion. The hub portion includes apertures to reduce the weight of the wheel. The axle housing portion protects a motorcycle axle from debris passing through the apertures in the hub portion, and stiffens the axle bearing supports.