Abstract: A bicycle suspension system of the present invention generally includes a bicycle suspension and a hydraulic control assembly. The hydraulic control assembly includes a fluid pump, a fluid responder and a fluid path. The fluid pump is mountable to a bicycle handlebar. The fluid responder is mountable to the bicycle suspension. The fluid path links the fluid pump and the fluid responder. The fluid responder is operatively connected to the bicycle suspension to operate the bicycle suspension between first and second suspension settings in response to fluid displacement between the fluid pump and the fluid responder.

Abstract: A pawl for controlling the rotation of a gear in a planetary gear mechanism. The pawl includes a nose and first and second pivot axes. The nose is engageable with the gear. The pawl is rotatable about the first pivot axis between a first mode permitting rotation of the gear in a first direction and a second direction and a second mode preventing rotation of the gear in the first direction. The pawl is rotatable about the second pivot axis to permit rotation of the gear in the second direction while the pawl is the second mode.

Abstract: A handlebar-steered suspension fork that includes an outer tube and an inner tube reciprocally slidable within the outer tube. The outer tube includes at least one radial load region and at least one transition region. A fiber-reinforced material is wrapped about at least one of the outer tube radial load regions and not wrapped about at least one of the outer tube transitions regions.

Abstract: A valve for a suspension damping system having a valve body and a shim valve assembly that permits fluid flow in two directions. The valve body separates a first fluid chamber from a second fluid chamber and has at least one fluid port therethrough between the first and second chambers. The shim valve assembly is coupled to the valve body and configured to control fluid flow across the valve body. The shim valve assembly includes a first shim having at least one fluid port and a second shim configured to seal the first shim fluid port. The first and second shims are flexible in a first direction under fluid pressure to permit fluid flow between the first and second fluid chambers, providing a first resistance to fluid flow. The second shim seals fluid flow through the first shim fluid port during flow in the first direction. The second shim is flexible in a second direction under fluid pressure to permit fluid flow between first and second fluid chambers, providing a second resistance to fluid flow.

Abstract: A method of varying a rest position and a length of an actuation arc of a lever in a hydraulic disc brake system. The hydraulic disc brake system comprises a master cylinder including a cylinder having a first end and second end and a port communicating with a hydraulic fluid reservoir between the first and the second cylinder ends. A piston is received in the cylinder. The piston has a seal between the cylinder and the piston and the piston is movable within the cylinder by a lever operatively associated therewith to selectively pressurize hydraulic fluid within the cylinder by moving the seal between the port and the second end of the cylinder. The hydraulic disc brake system further comprises a caliper in fluid communication with the master cylinder. The caliper has a pair of brake pads operatively associated with a disc received therebetween. The caliper is actuated by movement of the lever in an actuation arc between a rest position and an engagement point with the pads in engagement with the disc.

Abstract: A master cylinder assembly for a hydraulic actuation system for a handlebar-steered vehicle. The assembly includes a housing mountable to a frame member of the handlebar-steered vehicle and having a chamber including a fluid cavity with first and second regions. The first region is in fluid communication with the hydraulic actuation system. A piston is slidably disposed in the fluid cavity. An actuator is operatively connected to the housing and operatively connected to the piston to slidably displace the piston between an open fluid circuit position and a closed fluid circuit position. A first seal is disposed on either the piston or a wall of the fluid cavity. The first seal is configured to be in sealing engagement between the fluid cavity and the piston with the piston in the closed fluid circuit position to block fluid flow between the first and second fluid cavity regions.

Abstract: A bicycle transmission assembly that is mountable to a bottom bracket shell of a bicycle frame. The bicycle transmission assembly includes an input crank assembly, an output chainring, a planetary gear mechanism, a control system and a mounting system. The input crank assembly is mounted to a rotatable crank axle mounted to the bottom bracket shell. The planetary gear mechanism is mounted to the bottom bracket shell and provides a plurality of transmission paths. The planetary gear mechanism includes a sun gear, a ring gear and a locking element operatively connecting the sun gear and the ring gear. The control system is operatively connected to the planetary gear mechanism for selecting one of the transmission paths.

Abstract: A gas spring suspension system that maximizes the travel of the suspension system. The suspension system includes an outer tube and an inner tube slidable within the outer tube. A piston assembly is slidably mounted in the inner tube to sealingly separate a positive spring and a negative gas chamber. A floating piston is slidably mounted in the inner tube to separate a gas chamber from the negative gas chamber. The positive spring biases the inner and outer tubes apart from each other and the negative gas chamber biases the inner and outer tubes toward each other. The floating piston is configured to slidably displace within the inner tube in response to pressure differentials between the negative gas chamber and the gas chamber.

Abstract: A master cylinder for a bicycle hydraulic disc brake comprises a housing defining a cylinder, the cylinder having a first and a second end along its axis. A hydraulic fluid reservoir has a port between the hydraulic fluid reservoir and the cylinder, the port having an opening between the first and second cylinder ends. A piston having a seal resides in the cylinder with the seal between the piston and the cylinder. The seal has a leading seal edge with the leading seal edge being movable solely between the first cylinder and the port opening to vary the dead band distance between the leading seal edge and the port opening with the piston in a starting position. A lever is pivotably associated with the housing and operatively associated with the piston for moving the piston within the cylinder between the starting and a pressurized position as the lever is actuated between a rest position and an actuated position.

Abstract: A method of adjusting a lever actuated bicycle hydraulic disc brake master cylinder. The disc brake master cylinder has a housing defining a cylinder having first and second ends and a port communicating with a fluid reservoir between the first and second ends. A piston is received in the cylinder and the piston has a seal having a leading seal edge between the piston and the cylinder. The lever is operatively associated with the piston to move the piston from an unactuated position with the leading seal edge a select distance between the port and the first end of the cylinder to an actuated position between the port and the second end of the cylinder.

Abstract: A bicycle transmission assembly that is mountable to a bottom bracket shell of a bicycle frame. The bicycle transmission assembly includes an input crank assembly, an output chainring, a planetary gear mechanism, a control system and a mounting system. The planetary gear mechanism is mounted coaxially about an axis of the bottom bracket shell and provides a plurality of transmission paths. The control system is operatively connected to the planetary gear mechanism for selecting one of the transmission paths. The mounting system mounts the planetary gear mechanism and the control system to the bottom bracket shell. The mounting system includes at least one attachment point disposed on at least one frame boss extending radially outwardly from the bottom bracket shell. The control system is mounted nonrotatably to the at least one attachment point.

Abstract: A bicycle transmission assembly that is mountable to a bottom bracket shell of a bicycle frame. The bicycle transmission generally includes an input crank assembly, an output chainring, a planetary gear mechanism, a control system and a mounting system. The output chainring engages a bicycle drive chain that includes a plurality of chain links. The planetary gear mechanism includes a ring gear and provides a plurality of transmission paths. The planetary gear mechanism is mounted coaxially about the shell axis. The control system is operatively connected to the planetary gear mechanism for selecting one of the plurality of transmission paths. The mounting system mounts the planetary gear mechanism and the control system to the bottom bracket shell. At least one chain link overlaps the ring gear as viewed along the shell axis. The at least one chain link engages the output chainring.

Abstract: A reach-adjustable lever assembly mounted to a handlebar for actuating one of a gear-change and braking device. The lever assembly generally including a support member, a lever pivotably connected to the support member and a reach adjust mechanism. The reach adjust mechanism includes a follower, a cam and a cam seat for retaining the cam in a current user-selectable position. The follower is fixedly supported on one of the support member and the lever and the cam is rotatably supported on the other of the support member and the lever. The cam has a plurality of user-selectable positions. The lever is rotatably biased toward a rest position to position the cam against the follower. The cam and the follower are configured to provide a different rest position of the lever for each of the user-selectable positions.

Abstract: A bicycle multi-gear cassette mountable to a wheel hub driver mechanism that includes truncated conical shell having a first opening proximate a small shell base and a second opening proximate a large shell base. The openings are coaxial with an axis of the shell. A plurality of toothed sprockets having different numbers of teeth are disposed on the shell and extend radially of the central axis. A torque load transmitting profile is configured on the shell proximate one of the small and large shell bases. A radial load transmitting profile is configured on the shell proximate one of the small and large shell bases. The shell, sprockets, and the load transmitting profiles embody a single piece.

Abstract: A bicycle multi-gear cassette mountable to a wheel hub that generally includes a truncated conical shell and a plurality of toothed sprockets having different numbers of teeth. The shell includes a plurality of coaxial annular cylinders of variable diameter extending along an axis of the shell and a plurality of coaxial annular discs of variable diameter extending radially of the axis. The cylinders and discs are alternatingly arranged in a stepped sequence. The toothed sprockets are disposed on the shell and extend radially of the shell axis. At least one of the toothed sprockets includes a recess on a side facing an adjacent toothed sprocket having a smaller number of teeth. The recess includes a first region having a first depth and a second region having a second depth. The first depth is greater than the second depth. The shell and the plurality of toothed sprockets embody a single piece.

Abstract: A bicycle multi-gear cassette mountable to a wheel hub driver mechanism that includes truncated conical shell having a first opening proximate a small shell base and a second opening proximate a large shell base. The openings are coaxial with an axis of the shell. A plurality of toothed sprockets having different numbers of teeth are disposed on the shell and extend radially of the central axis. A torque load transmitting profile is configured on the shell proximate one of the small and large shell bases. A radial load transmitting profile is configured on the shell proximate one of the small and large shell bases. The shell, sprockets, and the load transmitting profiles embody a single piece. The torque load transmitting profile forms a featureless contact surface for frictional engagement with the hub driver mechanism.

Abstract: A reach-adjustable lever assembly that is mountable to a handlebar for actuating one of a gear-change and braking device. The lever assembly includes a lever with a finger grip pivotably connected to a housing and a reach adjust mechanism. The reach adjust mechanism includes a cam actuator and a cam. The cam actuator is rotatably supported by one of the housing and the lever. The cam is threadably connected to the cam actuator and is configured to engage the other of the housing and the lever. The cam is displaceable upon rotation of the cam actuator to pivot the lever to position the finger grip relative to the handlebar.

Abstract: A master cylinder lever for a hydraulic disc brake comprises a lever pivotally connected to a master cylinder housing and a bar clamp attached to the master cylinder housing for attaching the master cylinder housing to a bicycle handle bar along a longitudinal clamp axis. A cylinder wall is associated with the master cylinder housing, the cylinder wall comprising a cylinder interior and a cylinder exterior extending axially of a cylinder axis. A reservoir is associated with the master cylinder housing and is in fluid communication with the cylinder interior through a port in the cylinder wall. The reservoir comprises only a radial portion of the cylinder exterior. A piston within the cylinder has a seal operatively associated therewith.

Abstract: A sprocket assembly that includes at least three sprockets and a sprocket carrier having a plurality of radially extending carrier arms. The carrier arms include a first receiving surface and a second receiving surface opposite the first receiving surface. A first sprocket mounted to the first receiving surface and a second sprocket mounted to the second receiving surface. A third sprocket arranged between the first and second sprockets.

Abstract: A bicycle suspension system including a travel adjustment apparatus. The bicycle suspension system includes a piston tube and a piston assembly slidably disposed in the piston tube forming a shock-absorbing mechanism. The piston assembly is in contact with the piston tube. The travel adjustment apparatus includes first and second fluid chambers, a fluid valve mechanism for controlling fluid flow between the first and second fluid chambers, and an actuating assembly operatively connected to the fluid valve mechanism operable between at least two rider-selectable travel settings to operate the fluid valve mechanism between at least two valve settings corresponding to the rider-selectable travel settings.