Abstract: A steer/brake system for a vehicle (with wheels and/or tracks) is disclosed. The system may comprise a steering system with an operator control and braking system for each side of the vehicle with a master cylinder for the brake mechanism and an interface between the braking system and the operator control. Operation may provide a phase where the interface is at least partially engaged and force may be applied through the interface to the master cylinder to engage the brake mechanism to provide modulation for the operator control. A steering emulation system may comprise the interface and a compliant element configured to provide modulation for the operator control. The system may comprise a shared hydraulic system; the brake mechanism may comprise the steering brake mechanism and the service brake mechanism.

Abstract: A steer/brake system for a vehicle (with wheels and/or tracks) is disclosed. The system may comprise a steering system with an operator control and braking system for each side of the vehicle with a master cylinder for the brake mechanism and an interface between the braking system and the operator control. Operation may provide a phase where the interface is at least partially engaged and force may be applied through the interface to the master cylinder to engage the brake mechanism to provide modulation for the operator control. A steering emulation system may comprise the interface and a compliant element configured to provide modulation for the operator control. The system may comprise a shared hydraulic system; the brake mechanism may comprise the steering brake mechanism and the service brake mechanism.

Abstract: A steer/brake system for a vehicle (with wheels and/or tracks) is disclosed. The system may comprise a steering system with an operator control and braking system for each side of the vehicle with a master cylinder for the brake mechanism and an interface between the braking system and the operator control. Operation may provide a phase where the interface is at least partially engaged and force may be applied through the interface to the master cylinder to engage the brake mechanism to provide modulation for the operator control. A steering emulation system may comprise the interface and a compliant element configured to provide modulation for the operator control. The system may comprise a shared hydraulic system; the brake mechanism may comprise the steering brake mechanism and the service brake mechanism.

Abstract: A brake master cylinder comprising a housing having an inner surface defining a bore, and a piston movable in the bore along a piston axis. The piston includes two spaced apart lands defining the radially outermost surfaces capable of contacting the inner surface. At least one of the lands is longitudinally curved at the radially outermost surface. For example, the land can be curved at a radius of less than 1 inch (e.g., between 0.15 inch and 0/75 inch) and preferably less than 0.5 inch. In one embodiment, the longitudinally curved land includes two edges that define an axial length of the land. The two edges have a radius of less than 0.2 inch, and preferably about 0.1 inch. The relative position of the edges and lands is such that neither of the two edges is capable of contacting the inner surface of the bore during reciprocating movement of the piston in the bore.

Abstract: The present invention provides a disk brake system comprising a wheel defining a rotational axis, a caliper mounted adjacent the wheel, and a rotor mounted for rotation with the wheel and engageable by the caliper. The rotor includes a mounting slot defined by first and second sidewalls, the first sidewall defining a first axis that substantially intersects the rotational axis, and the second sidewall defining a second axis that is substantially parallel to the first axis. Preferably, the mounting slot defines a center axis that intersects a radial axis of the wheel at an angle of at least 1.5 degrees, preferably at least 2.0 degrees and more preferably about 2.5 to 3.9 degrees. Preferably, the mounting slot has a width and a length that is at least 10% larger, preferably at least 15% larger, and more preferably about 20% larger than the width.

Abstract: The present invention provides a power assist steering system for a vehicle having a wheel. The steering system includes a first reciprocating member coupled to the wheel such that reciprocating movement of the first reciprocating member provides turning movement of the wheel, a steering input engaged with the first reciprocating member such that rotation of the steering input provides reciprocating movement of the first reciprocating member, and a steering assist assembly including a second reciprocating member engaged with the steering input such that reciprocating movement of the second reciprocating member provides an assist force to the steering input. Preferably, the first and second reciprocating members engage the steering input at locations opposed to each other and also move along paths that are substantially parallel to each other.

Abstract: Disclosed herein is a hydraulic master cylinder body having a bore defined at least in part by a bore wall, wherein the bore wall includes an opening for hydraulic fluid to be passed into the bore, and a piston assembly situated at least substantially in the bore, the assembly having a piston with a piston body and at least one cup seal situated substantially around the piston body, the cup seal situated adjacent to the bore wall so as to be in sealing engagement therewith, and a back-up ring that is situated about the piston body, wherein the back-up ring is positioned to at least partially cover a portion of the cup seal that is adjacent to the bore wall and to prevent at least a portion of the cup seal from contacting the bore wall and the opening for hydraulic fluid during piston actuation.

Abstract: A brake caliper assembly comprising a housing including inlet and outlet ends collectively defining forward and rearward directions. The housing includes an abutting surface facing in the rearward direction and positioned closer to the inlet end than to the outlet end. A pad assembly includes an engaging surface in engagement with the abutting surface to thereby substantially prevent movement of the pad assembly in the forward direction. The outlet end of the housing is free from a feature that substantially prevents movement of the pad assembly in the forward direction. The pad assembly includes a base and a projection extending from the base in the rearward direction and defining the engaging surface. The outlet end of the pad assembly can include an alignment member extending in the forward direction and engaging the housing in a direction substantially perpendicular to the forward direction.

Abstract: A hydraulic steering assist assembly is provided for a vehicle with a mechanical steering assembly operable by a user to steer the vehicle. The hydraulic steering assist assembly includes a hydraulic actuator adapted to be coupled to the mechanical steering assembly and has a first side and a second side. A bi-directional hydraulic pump is placed in fluid communication with the first side and the second side of the hydraulic actuator. The hydraulic steering assist assembly further includes a valve in fluid communication with the first side and the second side of the hydraulic actuator, and a control system for controlling the bi-directional hydraulic pump and the valve. The bi-directional hydraulic pump provides a pressurized fluid to the hydraulic actuator, which applies a force on the mechanical steering assembly to assist steering the vehicle. The valve can act as a steering damper.

Abstract: A hydraulic brake actuator adapted to be mounted on a vehicle handlebar and hydraulically coupled to a brake mechanism. The brake actuator includes a brake base adapted to be secured to the handlebar, and a reservoir adapted to be coupled to the brake base and containing brake fluid, the reservoir having a bottom surface. The hydraulic brake actuator further includes a piston-cylinder assembly coupled to the reservoir, a brake lever movable relative to the brake base between a released position and an actuated position, and a locking pawl positioned to limit movement between the brake lever and the piston-cylinder assembly, the locking pawl being at least partially positioned directly below the bottom surface of the reservoir.

Abstract: A hydraulic brake assembly comprising a fluid conduit containing hydraulic fluid, a cylinder having a port fluidly connected to the conduit, and a piston positioned in the cylinder. The piston includes a recess having a depth at least 30% of a length of the piston. The assembly further includes a rod having an inner end positioned in the recess and an outer end outside the recess. In one embodiment, the piston moves relative to the cylinder along an axis, and the piston further includes a primary piston seal and a secondary piston seal separated by a seal spacing. The rod can axially overlap the secondary piston seal. For example, the inner end of the rod can be positioned axially between the primary piston seal and the secondary piston seal, and is preferably axially closer to the primary seal than to the secondary seal.

Abstract: Disclosed herein is an adjustable lever assembly with a lever having an adjustment section and a grip section, where the adjustment section includes a slide passage in communication with an adjuster passage, and an adjuster positioned at least partially inside the adjuster passage, the adjuster having a threaded inner passage extending therethrough. The adjustable lever assembly further includes a slide positioned substantially inside the slide passage, the slide including an outer wall surface that is keyed to the slide passage and a threaded outer portion for rotatably engaging the threaded inner passage of the adjuster, wherein rotation of the adjuster translates the slide about the adjuster passage, and wherein the slide includes a bottom portion configured for securing pivotally to a pushrod.

Abstract: A brake system comprising a brake disc that rotates about a center axis, a brake mount, a brake caliper attached to the brake mount and including a brake pad, and an adjuster between the brake mount and the brake caliper. The adjuster can move the brake pad toward and/or away from the brake disc. In one embodiment, the brake caliper is attached to the brake mount by a post extending through an elongated opening in the brake caliper and nonparallel to the center axis. The adjuster can change a relative location of the post within the elongated opening. The adjuster can include an end that extends into the elongated opening and works against the post. The post can include a fastener threaded to the brake mount in a direction substantially perpendicular to the center axis, and the fastener can extend through an elongated opening in the brake caliper.

Abstract: Disclosed herein is a hydraulic master cylinder body having a bore defined at least in part by a bore wall, wherein the bore wall includes an opening for hydraulic fluid to be passed into the bore, and a piston assembly situated at least substantially in the bore, the assembly having a piston with a piston body and at least one cup seal situated substantially around the piston body, the cup seal situated adjacent to the bore wall so as to be in sealing engagement therewith, and a back-up ring that is situated about the piston body, wherein the back-up ring is positioned to at least partially cover a portion of the cup seal that is adjacent to the bore wall and to prevent at least a portion of the cup seal from contacting the bore wall and the opening for hydraulic fluid during piston actuation.

Abstract: A brake caliper assembly comprising a housing including inlet and outlet ends collectively defining forward and rearward directions. The housing includes an abutting surface facing in the rearward direction and positioned closer to the inlet end than to the outlet end. A pad assembly includes an engaging surface in engagement with the abutting surface to thereby substantially prevent movement of the pad assembly in the forward direction. The outlet end of the housing is free from a feature that substantially prevents movement of the pad assembly in the forward direction. The pad assembly includes a base and a projection extending from the base in the rearward direction and defining the engaging surface. The outlet end of the pad assembly can include an alignment member extending in the forward direction and engaging the housing in a direction substantially perpendicular to the forward direction.

Abstract: A vehicle steering assembly comprising an input member, an output member, and a torsion bar coupling the input member to the output member. The torsion bar includes primary and secondary load structures, and the secondary load structure is inoperative below a transition torque. The primary load structure includes a primary torque member that constantly couples the input member to the output member throughout an operative range of the steering assembly. The secondary load structure includes first and second torque members that are separated by a gap when the assembly encounters a torque below the transition torque and that contact each other when the assembly encounters a torque above the transition torque. The first torque member can comprise a tubular structure surrounding the primary torque member. The tubular structure includes an opening defining a circumferentially-exposed surface, and the second torque member includes a radially-extending arm positioned in the opening.

Abstract: A hand control assembly comprising a base, an actuating mechanism movable relative to the base, a hub pivotally coupled to the base and positioned to move the actuating mechanism, a lever arm pivotally movable relative to the hub for movement about a pivot axis, and an adjusting mechanism positioned between the lever arm and the hub and adapted to adjust a space between the lever arm and a handlebar. The adjusting mechanism includes a dial mounted for rotation about an adjusting axis angled relative to the pivot axis. The dial and the lever arm cooperatively define a dimension corresponding with the dial protruding from the lever arm, and it is preferred that this dimension does not change when the dial is rotated from a short-reach position to a long-reach position. The dial can be mounted for rotation about an adjusting axis that is offset from an engaging member.

Abstract: A vehicle comprising a frame, a seat coupled to the frame, and left and right wheels. Left and right drive shafts transmit power to the left and right wheels, and an input shaft transmits power to the left and right drive shafts. A differential including a housing assembly receives power from the input shaft and divides the power between the left and right drive shafts. A speed sensor is positioned through (e.g., threaded) the housing assembly such that an inner end of the sensor is positioned inside the differential. In one embodiment, the speed sensor includes left and right speed sensors, and the at least two housings comprise a left housing and a right housing. Preferably, both the left speed sensor and the right speed sensor are positioned in one of the left housing and the right housing.

Abstract: A brake system comprising a brake disc that rotates about a center axis, a brake mount, a brake caliper attached to the brake mount and including a brake pad, and an adjuster between the brake mount and the brake caliper. The adjuster can move the brake pad toward and/or away from the brake disc. In one embodiment, the brake caliper is attached to the brake mount by a post extending through an elongated opening in the brake caliper and nonparallel to the center axis. The adjuster can change a relative location of the post within the elongated opening. The adjuster can include an end that extends into the elongated opening and works against the post. The post can include a fastener threaded to the brake mount in a direction substantially perpendicular to the center axis, and the fastener can extend through an elongated opening in the brake caliper.