Abstract: A riveted sprocket assembly that includes a sprocket carrier having a plurality of carrier arms and a plurality of sprockets attached to the carrier arms by rivets. First and second rivet heads of the rivets are countersunk into the carrier arms on one face and into the sprocket on the other face. The second rivet head is formed on the sprocket on the front face of the sprocket carrier. To prevent the riveting tool from damaging the sprocket during the riveting process, the rivet holes of the sprockets include a clearance portion around the second rivet head. This results in the sprocket having three-stepped rivet holes: a small diameter for the rivet shaft, an intermediate diameter for the rivet head and a larger diameter for the riveting tool. To minimize weight, the carrier arms narrow in a central region between radially inner and radially outer rivet holes on the carrier arms.

Abstract: A master cylinder for a hydraulic disc brake includes a housing defining a cylinder, the cylinder having a first and second end along its axis. A piston is received in the cylinder and has a radial seal between the piston and the cylinder. A lever is pivotably associated with the housing for pivoting between a rest position and an actuated position relative to the housing. A push rod is operatively associated with the piston and the lever to move the piston axially within the cylinder as the lever is actuated between the rest and actuated positions. A threaded engagement between a first end of the push rod and the lever is configured to cause movement of the rest position of the lever relative to the housing when a rotating force is applied to the push rod causing axial rotation of the push rod. An indexing structure is operatively associated with the push rod for providing index axial rotation of the push rod upon application of the rotating force to the push rod causing axial rotation of the push rod.

Abstract: A disc brake assembly is disclosed which is attachable to the wheel supporting portion of the frame of a cycle and which allows the orientation of the planar braking surface of the brake pad assembly to be infinitely variable within a defined range The disc brake assembly consists of a disc fixedly attached to a wheel, a plurality of brake pad assemblies each having a planar braking surface facing the disc and a caliper retaining the brake pad assemblies in an operative position. When braking occurs, the caliper advances at least one of the brake pad assemblies to bring the planar braking surfaces of the brake pad assemblies into and out of contact with the disc. In addition, means is disclosed for attaching each of the brake pad assemblies to the caliper with an orientation of the planar braking surface of the brake pad assembly being infinitely variable within a defined range.

Abstract: An axle assembly connecting a wheel assembly to a vehicle frame. The axle assembly includes a tubular body having first and seconds connectable to the vehicle frame and open-ended slots disposed proximate at least one of the first and second ends of the tubular body. An expansion element is engageable with the tubular body to radially deform the tubular body at a mounting point to the vehicle frame. This configuration provides a rigid connection between the axle assembly and the vehicle frame in both the linear and radial directions.

Abstract: A cable guide routing a control cable that extends between an actuator and a suspension system having a crown connecting two parallel tubular bodies to a steerer tube. The cable guide includes a housing formed on the crown and having a bore extending therethrough for receiving the control cable. The suspension system includes a spool located on an end of one of the tubular bodies for winding and unwinding the control cable. The housing is configured on the suspension system such that a portion of the control cable extending between the housing and the spool lies substantially in a plane of the spool. So configured, friction is minimized.

Abstract: A suspension system that includes a simplified lockout mechanism and an adjustable blow-off mechanism. The system includes a valve mechanism and a valve actuating assembly, a valve mechanism housing and a resilient member disposed between the valve mechanism and the valve mechanism housing. The valve mechanism is slidably mounted along the valve mechanism housing and it separates a first chamber from a second chamber. The valve actuating assembly operates the valve mechanism between open and closed positions. The resilient member is configured to be deformable by the valve mechanism as the valve mechanism is slidably displaced by an increasing pressure in the first fluid chamber. The sliding valve mechanism is configured to collide against the valve actuating assembly when a blow-off pressure is reached in the first fluid chamber switching the valve mechanism from the closed position to the open position.

Abstract: An apparatus comprising a body, an actuator assembly and an actuator control assembly. The body is attached to a handlebar of a handlebar-steered vehicle. The actuator assembly includes a lever arm in pivoting engagement with the body about a pivot axis spaced apart from an axis of a handlebar to which the body is attached. The lever arm is associated with a suspension adjust cable. The actuator control assembly includes a locking assembly and an adjustment assembly. The locking assembly is associated with each of the body and the actuator assembly. The locking assembly is capable of preventing pivoting of the actuator relative to the body in a first position corresponding to a first suspension setting. The adjustment assembly is associated with each of the body and the actuator assembly. The adjustment assembly is capable of preventing pivoting of the actuator relative to the body in a second position corresponding to a second suspension setting.

Abstract: A bicycle chainwheel assembly that includes at least one smaller chainwheel and at least one larger chainwheel, the chainwheels engageable by a chain. The larger chainwheel includes a first tooth and a second tooth disposed adjacent the first tooth opposite a drive rotation direction. The first tooth and the second tooth have a configuration that improves the shifting of a chain from a smaller chainwheel to the larger chainwheel. The first tooth has a lateral recess and the second tooth has a deflection chamfer. The second tooth may also have a recess. The first and second teeth have a configuration that prevents the first and second teeth from capturing the chain. An inner link plate of the chain includes a chamfer disposed on an outer side surface in a central region of the plate.

Abstract: A master cylinder for a bicycle hydraulic disc brake includes a cylinder wall defining a cylinder interior and a cylinder exterior. A piston is received within the cylinder interior. A reservoir for hydraulic fluid is defined in part by a portion of the cylinder exterior, the portion of the cylinder exterior protruding into the reservoir. A port through the portion of the cylinder exterior which protrudes into the reservoir provides fluid communication between the reservoir and the cylinder interior. The port is located on the portion of the cylinder exterior which protrudes into the reservoir at a position which prevents air bubbles within the reservoir from entering the port.

Abstract: An integral rider control device mountable to a handlebar steered vehicle. The control device includes an integral support structure having a left end for receiving a left handgrip and a right end for receiving a right handgrip. A central section is disposed between the left end and the right end. A plurality of non-tubular receptacles are formed in the integral support structure between the left end and the right end thereof. Each of the receptacles are configured to receive a respective piece of equipment. The equipment may include controls, displays or accessories. A connecting member is molded into the central section and outwardly extends from the central section. The connecting member pivotally couples the integral support structure to the vehicle along a steering axis of the vehicle.

Abstract: A master cylinder for a bicycle hydraulic disc brake includes a cylinder having a port in fluid communication with a hydraulic fluid reservoir. The port opens to the cylinder between first and second ends of the cylinder. A piston within the cylinder is movable between a select starting position with the seal between the first end of the cylinder and the port opening with the piston a select distance from the port opening and a pressurized position with the seal between the port opening and the second end of the cylinder. A dead-band adjustment structure is operatively associated with the piston for moving the select starting position to adjust the select distance between the port opening and the seal. A lever is pivotably attached to the housing and is operatively associated with the piston to move the piston between the select starting position and the pressurized position as the lever is pivoted between a rest position and a fully-actuated position.

Abstract: The invention relates to a closure member for an opening in an assembly on a housing for a bicycle gear box. Said closure member, consisting of a rubber elastic material, is captively connected to the housing by an extension and can be swung open and closed in a similar manner to a hinge. The confirmation can be optically improved by the formation of an upper lip.

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 shifting device including first and second shift control members, a takeup element, a holding member, and a release member. The takeup element configured for winding and unwinding a tensioned control cable. The first control member is rotatable about a handlebar and configured to rotate the takeup to at least pull or wind the control cable onto the takeup. The second control member is a return-to-neutral member for rotating the takeup to release the. The holding member is rotatable with the takeup and retains the takeup in select angular positions. The release member is operable for disengaging the holding member in response to the actuation or return stroke of the second control member for allowing the takeup to unwind the cable a sufficient amount to enable a single gear shift.

Abstract: A bicycle suspension system that includes an indicator for displaying the travel of a bicycle suspension system in response to an applied load. The system includes an inner tube telescopically engaging with the outer tube along an axis. A biasing mechanism biases the inner and outer tube apart from each other along the axis. The indicator is disposed along a length of the inner and outer tubes. The indicator may include a plurality of markings on the inner tube and a pointer on the outer tube. Each marking corresponds to a distance that the inner and outer tubes may be displaced relative to each other. The suspension system may include an adjustment mechanism that adjusts the distance the inner and outer tubes may be displaced relative to each other in response to an applied load. The rider may select the desired travel by actuating the adjustment mechanism to align the marking corresponding to the desired travel with the pointer.

Abstract: An electronic shifter for shifting a bicycle gear mechanism between a plurality of gears and using a relative shifting method. The shifter includes a stationary member mountable on a handlebar of the bicycle and a rotatable member rotatable with respect to the stationary member to define predetermined positions of the members with respect to each other. An electrical switch is operatively connected to the rotating member for generating a shift signal in response to the rotating member rotating from one predetermined position to another predetermined position.

Abstract: An integral rider control device coupled to a handlebar steered vehicle includes an elongate integral support structure having receptacles and non-cylindrical mounting surfaces, and a central region of the structure configured to pivotally couple to the vehicle. Each receptacle is configured to integrally receive at least one accessory, control or display. The mounting surfaces are configured for the integral attachment of the accessories, controls and displays. The device can include upper and lower elongate spars. An integrated rider control system includes an elongate stem, the structure pivotally coupled to the stem, and two mandrels outwardly projecting from left and right ends of the structure. A cushionable cover connected to the structure. A rider control device includes an elongate member having at least two gripping surfaces and an elongate open recess defined into the member and configured to receive one of integrally attached accessories, controls and displays.

Abstract: An electronic shifter for shifting a bicycle gear mechanism between a plurality of gears and using a relative shifting method. The shifter includes a stationary member mountable on a handlebar of the bicycle and a rotatable member rotatable with respect to the stationary member to define predetermined positions of the members with respect to each other. An electrical switch is operatively connected to the rotating member for generating a shift signal in response to the rotating member rotating from one predetermined position to another predetermined position.

Abstract: A brake operating device (30) is configured such that actuation of the brake lever (34) around the lever pivot (36) displaces the cable (38) in a direction transverse to the cable length toward the lever pivot (36), as the user is actuating the brake lever (34). This provides at least a 33% increase in mechanical advantage over the actuation range of the brake lever (34).

Abstract: A gear indicator for a bicycle that includes first and second control cables connected to first and second shift actuators, respectively. The gear indicator includes a housing mounted onto the control cables. The housing is spaced apart from the shift actuators and is not attached to the handlebars. First and second pulleys are disposed in the housing and are rotatable by a displacement of the first and second control cables, respectively. First and second gear display elements are movable in response to the rotation of the first and second pulleys. The first and second display elements indicate the currently selected gears of the bicycle.