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 crankshaft drive for an internal-combustion engine includes a crankshaft, a connecting rod assembly coupled to the crankshaft, and a balancing shaft arranged parallel to the crankshaft and at a distance r from the crankshaft. A balancing weight extends from the balancing shaft for balancing mass forces caused by the rotation of the crankshaft. A recess is formed in the balancing weight, so that during rotation of the balancing shaft, the balancing weight does not interfere with the rotating crankshaft and connecting rod assembly. The inclusion of the recess allows the distance r between the crankshaft and the balancing shaft to be reduced. Preferably, a rib is formed on one side of the balancing shaft to strengthen the balancing shaft.

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 transmission shifter assembly including a cam drum having at least two pins extending therefrom, and a shift mechanism engageable with the pins. The shift mechanism includes a tooth that is operable to engage a first one of the pins to rotate the drum in a first direction and a stop that is operable to engage a second one of the pins to prevent over-rotation of the drum in the first direction. Preferably, the shift mechanism includes a shift pawl and a shift lever and the stop is mounted on either the shift pawl or the shift lever. Additionally, the shift mechanism can include a second stop mounted on the other of the shift pawl or the shift lever, the second stop being operable to engage a third one of the pins to prevent over-rotation of the drum in a second direction.

Abstract: A motorcycle engine includes a crankshaft rotating in response to the reciprocation of pistons in cylinder bores. The inertial effects of the reciprocating pistons cause vibrations in the engine. A pair of balancer shafts are provided on opposite sides of the crankshaft, and are driven by the crankshaft through a drive member, such as a chain or belt. The balancer shafts are supported for rotation by bearings in the left side of the engine's crankcase, and by bearings in bearing housings that are mounted to the left side of the engine's crankcase. Thus, the balancer shafts are substantially only supported for rotation by the left side of the crankcase.

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.

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: A rocker assembly includes a base member having opposite ends, a flange interconnected with each of the opposite ends, a pair of rocker arm support shafts supported by the flanges, and a rocker arm interconnected with each rocker arm support shaft for rotation with respect to the rocker arm support shaft about a longitudinal axis. The rocker assembly is housed in a rocker box housing, is removable from the rocker box housing, and is mounted directly on the cylinder head of a motorcycle. The rocker box housing includes a generally wedge-shaped cover and a generally wedge-shaped base to allow the cover to be removed from the base in a generally horizontal direction.

Abstract: An adjustable motorcycle windshield includes an actuating assembly including first and second actuating members that are preferably bell cranks mounted for rotation. Each actuating member actuates an upper and a lower extension arm to selectively move the windshield. The upper arms move the windshield farther than the lower arms, resulting in the inclination of the windshield being changed. The actuating assembly also includes connecting members connecting the upper arms to the windshield. A slot is provided in a frame member, and the connecting point between the upper arms and the connecting members translates in the slot as the windshield is being adjusted. Resilient lower windshield mounts are provided that permit limited rotation of the windshield during adjustment.

Abstract: A motorcycle includes a frame having an aperture, and a seat having an insert member that is inserted into the aperture to at least partially substantially secure the seat to the frame. A strap defines a loop surrounding a portion of the seat. The strap is manually releasably attached to the frame by way of a coupling member and a bushing having a biasing member. The coupling member includes an opening having an enlarged clearance portion and a reduced retaining portion, and the biasing member includes a split ring constructed of spring steel. When the bushing is positioned within the retaining portion of the opening with the split ring in the second condition, the biasing member resists movement of the coupling member. Manually-operable thumb screws are provided to permit quick attachment and release of the seat to the frame.

Abstract: An intergated secruity, tip-over, and turn signal system for a motorcycle. The system provides multiple-functions with one control unit and a simplified wiring network. The system provides vehicle turn signal control including automatic turn-off of turn signal lamps at the end of a turn. The systems monitors the lateral forces acting on the motorcycle and disables the turn signal lamps, starter system, and fuel system when a tip-over condition is detected. For theft deterrence and prevention, the system allows a rider to disable the vehicle starter and ignition systems while the vehicle is parked. Tamper sensors in the system activate turn signals and an audible alarm if tampering is detected.

Abstract: A rocker support assembly for a motorcycle internal combustion engine. The assembly comprises a pair of rockers positioned in spaced relation from each other, a breather housing, and a pressure-responsive member. The housing at least partially defines an inlet aperture, an outlet aperture, and a passage in fluid communication between the inlet aperture and the outlet aperture. The passage is positioned substantially between the rockers. The pressure-responsive member is disposed in the passage and is operable in response to pressure differences in the passage to permit or inhibit fluid flow through the passage from the inlet to the outlet. A filter element is disposed within the housing such that substantially all fluid flowing from the inlet aperture to the outlet aperture passes through the filter element.