Abstract: A rod-end front suspension is provided for an off-road vehicle. The rod-end front suspension comprises a spindle assembly that is pivotally coupled with an upper suspension arm by way of a first rod-end joint and pivotally coupled with a lower suspension arm by way of a second rod-end joint. A steering rod-end joint coupled with the spindle assembly pivotally receives a steering rod. An axle assembly coupled with the spindle assembly conducts torque from a transaxle to a wheel coupled with the spindle assembly. Each of the first and second rod-end joints comprises a ball rotatably retained within a casing. The ball is fastened within a recess between parallel prongs extending from the spindle assembly. A threaded shank extending from the casing is threadably fixated with the suspension arm, such that the spindle assembly may be moved with respect to the casing and the suspension arm.

Abstract: A leading-edge steering system is provided for a front suspension of an off-road vehicle. The leading-edge steering system is comprised of a spindle assembly that supports a drive axle assembly to conduct torque from a transaxle to a front wheel. A first rod-end joint pivotally couples an upper suspension arm and the spindle assembly, and a second rod-end joint pivotally couples a lower suspension arm and the spindle assembly. A steering rod-end joint pivotally couples a first end of a steering rod with a leading-edge portion of the spindle assembly. A steering gear is coupled with a second end of the steering rod and configured to move the steering rod, such that the spindle assembly rotates with respect to the upper and lower suspension arms. The leading-edge portion is configured to exert primarily tensile forces on the steering rod during travel over rough terrain.

Abstract: An apparatus and methods are provided for a chassis for an off-road vehicle that includes a chassis strut support. The chassis is a welded-tube variety of chassis that includes a front portion and a rear portion that are joined to an intervening passenger cabin portion. The chassis strut support includes one or more pairs of rear strut gusset plates for distributing loading on a rear strut crossmember by rear struts to at least a seat crossmember comprising the chassis. The rear strut gusset plates generally comprise thick sheet-members configured to be attached to a vertical brace between an upper mount and a lower stay comprising the chassis to reinforce the vertical brace and impart increased strength to the chassis. The rear strut gusset plates are configured to be attached to the vertical brace by way of bolts, rivets, welding, or any combination thereof.

Abstract: A vented roof panel is provided for an overhead portion of a roll-over protection system of an off-road vehicle. The vented roof panel comprises a planar member that includes a shape and a curvature that match the overhead portion to enable closely attaching the vented roof panel to the roll-over protection system. The planar member is formed of any of various plastics, such as injection molded plastic, or other similar materials. An air scoop including an air inlet port is centrally disposed in the planar member. The air inlet port is disposed in a forward-facing portion of the air scoop and configured to direct an airstream from outside to underneath the vented roof panel. The vented roof panel may be attached to tubular frame members comprising the roll-over protection system by way of one or more suitable fasteners.

Abstract: An apparatus and methods are provided for a transmission for a rear mid-engine vehicle. The transmission comprises a power transfer portion for receiving torque from the engine and a gearbox for providing conversions of rotational speed and torque. First and second side output portions conduct torque from the gearbox to the rear wheels. A forward output portion conducts torque to front wheels of a four-wheel drive vehicle. An air clutch comprising each output portion controls the degree of torque transferred to each wheel. The output portions are each coupled to a rear wheel by a rear axle, bevel gears, and rear portal gears. The rear axles are aligned with, and positioned above, the trailing arms to protect the rear axles from damage due to rocks and debris. The length and alignment of the rear axles cause CV joints to articulate in the same direction as the trailing arms.

Abstract: A leading-edge steering system is provided for a front suspension of an off-road vehicle. The leading-edge steering system is comprised of a spindle assembly that supports a drive axle assembly to conduct torque from a transaxle to a front wheel. A first rod-end joint pivotally couples an upper suspension arm and the spindle assembly, and a second rod-end joint pivotally couples a lower suspension arm and the spindle assembly. A steering rod-end joint pivotally couples a first end of a steering rod with a leading-edge portion of the spindle assembly. A steering gear is coupled with a second end of the steering rod and configured to move the steering rod, such that the spindle assembly rotates with respect to the upper and lower suspension arms. The leading-edge portion is configured to exert primarily tensile forces on the steering rod during travel over rough terrain.

Abstract: An apparatus and methods are provided for removing trapped air from a cooling system of an internal combustion engine. The apparatus includes an air bleed valve configured to allow the trapped air to be vented from a water jacket comprising an engine cylinder head. The air bleed valve is coupled with a hollow portion disposed at a top of the cylinder head. A topmost chamber within the hollow portion is in fluid communication with the water jacket. The water jacket includes angled upper walls near the hollow portion configured to direct the trapped air into the topmost chamber. An air bleed line is coupled with the air bleed valve and configured to direct the trapped air out of the topmost chamber to a suitable coolant reservoir.

Abstract: An apparatus and a method are provided for a camber adjustment assembly, comprising: first and second end plates coupled to a substantially planar center portion, wherein the first and second end plates comprise a generally triangular configuration; a chassis element coupled to a trailing arm and the camber adjustment assembly, and wherein a force may be applied to the camber adjustment assembly so as to desirably induce a positive or negative camber condition.

Abstract: A vented roof panel is provided for an overhead portion of a roll-over protection system of an off-road vehicle. The vented roof panel comprises a planar member that includes a shape and a curvature that match the overhead portion to enable closely attaching the vented roof panel to the roll-over protection system. The planar member is formed of any of various plastics, such as injection molded plastic, or other similar materials. An air scoop including an air inlet port is centrally disposed in the planar member. The air inlet port is disposed in a forward-facing portion of the air scoop and configured to direct an airstream from outside to underneath the vented roof panel. The vented roof panel may be attached to tubular frame members comprising the roll-over protection system by way of one or more suitable fasteners.

Abstract: An apparatus and methods are provided for a front structural bulkhead for improving the strength of an off-road vehicle chassis. The chassis is a welded-tube variety of chassis that includes a front portion and a rear portion that are joined to an intervening passenger cabin portion. Frontward stays and a bulkhead mount couple the front structural bulkhead to the front portion. Bulkhead mount pillars and a bulkhead mount crossmember couple the front structural bulkhead to the passenger cabin portion. The front structural bulkhead includes a modular chassis for supporting drivetrain components that are operably coupled with front wheels of the vehicle. The front structural bulkhead includes upper and lower mounting points configured to receive front suspension controls arms. The upper and lower mounting points are configured to allow the front wheels to move vertically due to the vehicle traveling over terrain.

Abstract: An apparatus and methods are provided for a rear portal trailing arm assembly for a vehicle rear suspension. The trailing arm assembly comprises a CV joint hub for coupling with a transaxle and a wheel hub for coupling with a rear wheel. A gear transfer case extends rearward from the CV joint hub to an axle case and functions similarly to a rear trailing arm. Forward mounts facilitate coupling the gear transfer case to the chassis such that the trailing arm assembly pivots vertically with respect to the chassis. A rearward mount facilitates coupling a strut with the gear transfer case to control the vertical motion of the rear wheel. Multiple gear assemblies are meshed within the gear transfer case. An axle is coupled with the meshed gear assemblies and housed within the axle case, such that torque applied to the CV joint hub is communicated to the wheel hub.

Abstract: An apparatus and methods are provided for a turbocharger intake system for an off-road vehicle. The turbocharger intake system comprises a turbocharger disposed at a rear of an engine of the vehicle, such that heat radiated from the turbocharger is directed rearward of the engine during operation of the vehicle. The turbocharger is coupled with an exhaust manifold for conducting exhaust gases from the engine to the turbocharger. An air intake duct is routed from an intake air filter canister to the turbocharger for conveying filtered air to the turbocharger. A suitable air filter is housed within the intake air filter canister so as to remove airborne particulate matter from the air entering the engine. The turbocharger drives charged intake air through an intercooler for lowering the temperature of charged intake air. The charged intake air is directed to combustion chambers of the engine by way of an intake manifold.

Abstract: An apparatus and methods are provided for an air-cooled CVT clutch. The air-cooled CVT clutch includes a first cooling fan coupled with a primary clutch and a second cooling fan coupled with a secondary clutch. An outboard housing mates with an inboard housing to enclose the primary clutch and the secondary clutch. The first cooling fan is coupled to a moveable sheave comprising the primary clutch and configured to draw a cooling airstream through an air duct disposed in the outboard housing. The second cooling fan is coupled to a moveable sheave comprising the secondary clutch and configured to draw the cooling airstream from the primary clutch to the secondary clutch. The first cooling fan pushes the cooling airstream to the secondary clutch when the second clutch is not rotating.

Abstract: An apparatus and methods are provided for suspending a rear-mounted drivetrain assembly in a chassis of an off-road vehicle. The apparatus includes one or more front mounts for coupling a frontmost portion of the drivetrain assembly to the chassis. The front mounts suspend the frontmost portion from a seat crossmember comprising the chassis. A rearmost portion of the drivetrain assembly is suspended from a rear portion of the chassis by way of a hanger. The hanger is coupled with the rear portion of the chassis by way of one or more mounts disposed on a pair of lower rear stays comprising the chassis. Experimentation has demonstrated that suspending the drivetrain assembly within the rear portion of the chassis prevents impacts on the bottom of the chassis from affecting drivetrain alignment.

Abstract: An apparatus and methods are provided for a front structural bulkhead for improving the strength of an off-road vehicle chassis. The chassis is a welded-tube variety of chassis that includes a front portion and a rear portion that are joined to an intervening passenger cabin portion. Frontward stays and a bulkhead mount couple the front structural bulkhead to the front portion. Bulkhead mount pillars and a bulkhead mount crossmember couple the front structural bulkhead to the passenger cabin portion. The front structural bulkhead includes a modular chassis for supporting drivetrain components that are operably coupled with front wheels of the vehicle. The front structural bulkhead includes upper and lower mounting points configured to receive front suspension controls arms. The upper and lower mounting points are configured to allow the front wheels to move vertically due to the vehicle traveling over terrain.

Abstract: An apparatus and methods are provided for a trailing arm for a rear suspension of an off-road vehicle. The trailing arm comprises an axle support that has a cylindrical shape for supporting roller bearings whereby a wheel hub is rotatable relative to the trailing arm. A joined control arm extends forward of the axle support to an outboard control arm and an inboard control arm. The outboard and inboard control arms are configured to hingedly couple to a chassis of the vehicle. An outboard chassis mount and an inboard chassis mount operate as pivots that place the trailing arm into a hinged relationship with the chassis. The tailing arm is configured to be interchangeable between a driver side and a passenger side of the off-road vehicle. Bulkheads are arranged within an interior chamber of the tailing arm and configured to impart structural integrity to the tailing arm.

Abstract: An apparatus and methods are provided for a chassis for an off-road vehicle that includes A-pillar supports. The chassis is a welded-tube variety of chassis that includes a front portion and a rear portion that are joined to an intervening passenger cabin portion. A front canopy is coupled to the front portion and reinforces the chassis during loading forces due to front struts. Each of the A-pillar supports includes a vertical brace disposed between the front canopy and a side brace of the vehicle. The vertical brace extends downward from the front canopy, adjacently to an A-pillar and a hinge pillar, to the side brace. The frontward stay extends forward from substantially a midpoint of the vertical brace to a joining of the A-pillar and the hinge pillar. The A-pillar supports reinforce the front canopy and provide structural integrity to a front of the passenger cabin portion.

Abstract: An apparatus and a method are provided for a camber adjustment assembly, comprising: first and second end plates coupled to a substantially planar center portion, wherein the first and second end plates comprise a generally triangular configuration; a chassis element coupled to a trailing arm and the camber adjustment assembly, and wherein a force may be applied to the camber adjustment assembly so as to desirably induce a positive or negative camber condition.

Abstract: An apparatus and methods are provided for a modular front drivetrain comprising a single assembly that may be installed onto and removed from a vehicle. The modular front drivetrain comprises a modular chassis supporting a transaxle, a front differential, and a steering gear for operating front wheels of the vehicle. The transaxle, the front differential and drive axles convey torque from an engine onboard the vehicle to the front wheels. A spindle assembly is coupled with each front wheel of the vehicle and pivotally joined with the modular chassis by way of a front suspension system. Steering rods coupled with the spindle assemblies horizontally rotate the front wheels according to operation of a steering wheel onboard the vehicle. The modular front drivetrain advantageously facilitates replacing an entire drivetrain and suspension assembly quickly and easily in the event of a part failure during racing applications.

Abstract: An apparatus and methods are provided for a portal spindle assembly for a vehicle front suspension. The portal spindle assembly comprises a spindle portion that is rotatably coupled with upper and lower connecting arms. A leading-edge portion is rotatably coupled with a steering rod-end joint, such that moving the steering rod-end joint rotates the spindle assembly with respect to the upper and lower connecting arms. An inboard case and an outboard case support a pinion gear assembly that is meshed with an output gear assembly for communicating torque from a constant velocity joint to a front wheel coupled to the output gear assembly. The pinion gear assembly is aligned along a pinion axis disposed at an angle with respect to a hub axis of the output gear assembly. The angle facilitates a suspension geometry that provides a camber change of the front wheel that eliminates a change in track width.