RECREATIONAL VEHICLE TOE STOP, TOE STOP ASSEMBLIES, AND METHODS OF ASSEMBLING A RECREATIONAL VEHICLE

Abstract

A toe stop is provided that includes a unitary body. The unitary body includes one or more of a forward wall; an inboard wall extending rearward from the forward wall; and a rearward wall extending upward inward from the inboard wall. A toe pocket is at least partially defined by the forward wall and the inboard wall.

Description

BACKGROUND

Snowmobiles are popular land vehicles used as transportation vehicles or as recreational vehicles in cold and snowy conditions. Generally, snowmobiles are available for various applications such as deep snow, high performance, luxury touring, and trail riding, for example. In general, a snowmobile has a chassis on or around which the various components of the snowmobile are assembled. Typical snowmobiles include one or more skis for steering, a seat, handlebars, and an endless track for propulsion mounted to a central chassis. The engine drives a ground-engaging endless track disposed in a longitudinally extending drive tunnel. One or more skis serve to facilitate steering as well as to provide flotation of the front of the snowmobile over the snow in which it is operated. A handlebar assembly, positioned forward of the seat, is operatively linked to the skis for steering the snowmobile. The skis may be pivoted to steer the snowmobile, for example, by turning the handlebars. The snowmobile also includes a footrest for the rider while riding.

SUMMARY

Embodiments include a toe stop that includes a composite body. The composite body includes a first portion defining a toe pocket; and a second portion at least partially defining a chamber positioned inboard of the toe pocket, wherein the chamber is shaped to at least partially house a vehicle component therein.

Embodiments further include a toe stop that includes a composite body. The composite body includes a first portion defining a toe pocket; and a wall positioned inboard of the first portion and extending rearward therefrom, wherein an inboard side of the wall defines a channel configured to receive at least a portion of a wire harness for an electrical component therein.

Embodiments include a toe stop that includes a composite body. The composite body includes a toe pocket; and a wall positioned inboard of the toe pocket and extending rearward therefrom, the wall defining a sensor mount.

Other embodiments include a toe stop that includes a unitary body. The unitary body includes a bottom flange forming a bottom surface of the top stop; a forward wall extending upward from the bottom flange; an inboard wall extending upward from the bottom flange and rearward from the forward wall; a rearward wall extending upward from the bottom flange and inward from the inboard wall. The toe pocket is partially defined by the forward wall and the inboard wall.

Embodiments include a snowmobile that includes a body including a tunnel; a running board assembly secured to the body, a support member positioned outboard of the tunnel, a foot support member having an inboard side removably secured to the body; and a toe stop coupled to the foot support member. The toe stop is a molded polymeric composite material.

Additional embodiments include a method of assembling a snowmobile that includes a body defining a tunnel. The method includes: attaching a support member to the tunnel using a first plurality of fasteners such that the support member is located outboard of the tunnel; attaching inboard sides of a foot support member to the tunnel using a second plurality of fasteners; and securing outboard sides of the foot support member to the support member using a plurality of flexible clips integrally formed with the foot support member that is defined on an outboard side of the foot support member; and attaching a toe stop to the foot support member using one or more second fasteners, the toe stop comprising a bottom flange with one or more slots, each slot configured to receive one of the second fasteners.

Embodiments include a method of assembling different snowmobiles with a common forward frame. The method includes providing a common forward frame including a toe stop mounting feature; providing a track drive shaft positionable with respect to the common forward frame in a first position for a first snowmobile, and a second position that is different than the first position for a second snowmobile; and securing a first toe stop to the toe stop mounting feature of the common forward frame when the track drive shaft is in the first position, or securing a second toe stop that is different than the first toe stop to the toe stop mounting feature of the common forward frame when the track drive shaft is in the second position.

BRIEF DESCRIPTION OF THE DRAWINGS

This written disclosure describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to illustrative embodiments that are depicted in the figures, in which:

FIG. 1 illustrates a side view of a first snowmobile, according to some embodiments.

FIG. 2 illustrates a perspective of the snowmobile of FIG. 1, according to some embodiments.

FIG. 3 illustrates a top view of the snowmobile of FIG. 1, according to some embodiments.

FIG. 4 illustrates a front view of the snowmobile of FIG. 1, according to some embodiments.

FIG. 5 illustrates a right side view of the snowmobile of FIG. 1 with portions of the engine cover removed, according to some embodiments.

FIG. 6 illustrates a right side perspective view of the snowmobile of FIG. 1 with portions of the engine cover removed, according to some embodiments.

FIG. 7 illustrates a top view of the snowmobile of FIG. 1 with portions of the engine cover removed, according to some embodiments.

FIG. 8 illustrates a right side view of a second snowmobile with portions of the engine cover removed, according to some embodiments.

FIG. 9 illustrates a right side perspective view of the snowmobile of FIG. 8 with portions of the engine cover removed, according to some embodiments.

FIG. 10 illustrates a top view of the snowmobile of FIG. 10 with portions of the engine cover removed, according to some embodiments.

FIG. 11 illustrates a perspective top view of the snowmobile chassis having a running board assembly connected thereto, according to some embodiments.

FIG. 12 illustrates an exploded top view of the running board assembly of FIG. 11, according to some embodiments.

FIG. 13 illustrates an exploded bottom view of the running board assembly of FIG. 11, according to some embodiments.

FIG. 14 illustrates an alternative perspective top view of the snowmobile chassis having the running board assembly attached to the tunnel, according to some embodiments.

FIG. 15A illustrates an isolated top view of the running board assembly, according to some embodiments.

FIG. 15B illustrates an isolated side view of the running board assembly, according to some embodiments.

FIG. 15C illustrates an isolated bottom view of the running board assembly, according to some embodiments.

FIG. 16 illustrate a cross section view of the running board assembly from line 16-16 in FIG. 15B, according to some embodiments.

FIG. 17A illustrates an exploded side view of the running board assembly, according to some embodiments.

FIG. 17B illustrates an isometric side view of the rear kick up assembly, according to some embodiments.

FIG. 18 illustrates a close up bottom view of the running board assembly, according to some embodiments.

FIG. 19 illustrates a bottom view of a foot support member of the running board assembly, according to some embodiments.

FIG. 20 illustrates a view of the forward end the foot support member of the running board assembly, according to some embodiments.

FIG. 21A illustrates a top view of the foot support member and a rear kick-up panel of the running board assembly, according to some embodiments.

FIG. 21B illustrates a bottom view of the foot support member and the rear kick-up panel of the running board assembly, according to some embodiments.

FIG. 22 illustrates a close-up bottom perspective view of a front end of the foot support member and support member of the running board assembly, according to some embodiments.

FIG. 23A illustrates a close-up bottom view of the foot support member and support member of the running board assembly, according to some embodiments.

FIG. 23B illustrates a close-up top view of the foot support member and support member of the running board assembly, according to some embodiments.

FIG. 24 illustrates another close-up bottom perspective view of the front end of the foot support member and support member of the running board assembly, according to some embodiments.

FIG. 25A illustrates a close-up bottom view of the foot support member of the running board assembly, according to some embodiments.

FIG. 25B illustrates a close-up top view of the foot support member of the running board assembly, according to some embodiments.

FIG. 26 illustrates an inboard view of a front toe stop of the running board assembly, according to some embodiments.

FIG. 27A illustrates a top perspective view of the front toe stop, the foot support member, and the support member of the running board assembly, with the tunnel and a portion of the forward frame assembly not shown for illustrative purposes, according to some embodiments.

FIG. 27B illustrates a bottom perspective view of the front toe stop, the foot support member, and the support member of the running board assembly, with the tunnel and a portion of the forward frame assembly not shown for illustrative purposes, according to some embodiments.

FIG. 28 illustrates a front perspective view of the front toe stop, the foot support member, the support member of the running board assembly, and bottom-out protector, with a belt housing assembly in a first position associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 29 illustrates an alternative front perspective view of the front toe stop, the foot support member, the support member of the running board assembly, and bottom-out protector, with the belt housing assembly in a second position associated with the second snowmobile of FIG. 8, according to some embodiments.

FIG. 30 illustrates a side view of the assembly of FIG. 29, according to some embodiments.

FIG. 31 illustrates a top view of the assembly of FIG. 29, according to some embodiments.

FIG. 32 illustrates a rear view of the rear kick-up panel of the running board assembly, according to some embodiments.

FIG. 33 illustrates a bottom view of the rear kick-up panel of the running board assembly, according to some embodiments.

FIG. 34A illustrates a bottom view of the foot support member and the rear kick-up panel of the running board assembly in a first position associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 34B illustrates a top view of the foot support member and the rear kick-up panel of the running board assembly of FIG. 34A, according to some embodiments.

FIG. 35A illustrates a bottom view of the foot support member, the support member, and the rear kick-up panel of the running board assembly in a first position associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 35B illustrates a top view of the assembly of FIG. 35A, according to some embodiments.

FIG. 35C illustrates a bottom view of a foot support member in a second position associated with the second snowmobile of FIG. 8, according to some embodiments.

FIG. 36 illustrates a side view of the foot support member, the support member, and the rear kick-up panel of the running board assembly, according to some embodiments.

FIG. 37A illustrates a top view of a support bracket for the running board assembly associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 37B illustrates a side view of the support bracket of FIG. 37A, according to some embodiments.

FIG. 37C illustrates a top view of a support bracket for the running board assembly associated with the second snowmobile of FIG. 8, according to some embodiments.

FIG. 37D illustrates a side view of the support bracket of FIG. 37C, according to some embodiments.

FIG. 38 illustrates an end view of the support bracket of FIG. 37A, according to some embodiments.

FIG. 39 is a flowchart for a method of assembling a snowmobile, according to some embodiments.

FIG. 40A illustrates a perspective view of a snowmobile including a forward frame assembly, a heat exchanger assembly, and a tunnel, according to some embodiments.

FIG. 40B illustrates an exploded view of the snowmobile of FIG. 40A, according to some embodiments.

FIG. 40C illustrates a side view of the tunnel of FIG. 40A with the support bracket and support tube removed for viewing purposes, according to some embodiments.

FIG. 41A illustrates an engine being inserted into a forward frame assembly, according to some embodiments.

FIG. 41B illustrates right rear perspective view of a snowmobile forward frame assembly, according to some embodiments.

FIG. 41C illustrates left front perspective view of the snowmobile forward frame assembly, according to some embodiments.

FIG. 42A illustrates a right side view of the forward frame assembly with a belt housing assembly in a first position associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 42B illustrates a left side view of the forward frame assembly of FIG. 42A with a track drive shaft in a first position associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 42C illustrates a right side view of the forward frame assembly with the belt housing assembly in a second position associated with the second snowmobile of FIG. 8, according to some embodiments.

FIG. 42D illustrates a left side view of the forward frame assembly of FIG. 42C with a track drive shaft in a second position associated with the second snowmobile of FIG. 8, according to some embodiments.

FIG. 43 illustrates a schematic rear view of the tunnel, the support bracket, and the foot support member, according to some embodiments.

FIG. 44 illustrates a bottom view of the foot support member, the support member, and the rear kick-up panel of the running board assembly installed on the snowmobile in a first position associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 45 illustrates a close-up bottom view of the foot support member and the support member of FIG. 44, according to some embodiments.

FIG. 46 illustrates a side view of a forward frame assembly with a steering column and suspension components associated with the second snowmobile of FIG. 8, according to some embodiments.

FIG. 47 illustrates a side view of the forward frame assembly with a steering column and suspension components associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 48 illustrates a front view of the assembly of FIG. 46, according to some embodiments.

FIG. 49 illustrates a front view of the assembly of FIG. 47, according to some embodiments.

FIG. 50A illustrates a side view of the steering column assembly of FIG. 46, according to some embodiments.

FIG. 50B illustrates a front view of the steering column assembly of FIG. 50A, according to some embodiments.

FIG. 51A illustrates a side view of the steering column assembly of FIG. 47, according to some embodiments.

FIG. 51B illustrates a front view of the steering column assembly of FIG. 51A, according to some embodiments.

FIG. 52A illustrates a side view of the steering column assembly of FIG. 50A superimposed with the steering column assembly of FIG. 51A, according to some embodiments.

FIG. 52B illustrates a front view of the steering column assembly of FIG. 50B superimposed with the steering column assembly of FIG. 51B, according to some embodiments.

FIG. 53 illustrates a top-down view of the forward frame assembly, suspension, and engine components associated with the second snowmobile of FIG. 8, according to some embodiments.

FIG. 54 illustrates a top-down view of the forward frame assembly, suspension, and engine components associated with the first snowmobile of FIG. 1, according to some embodiments.

FIG. 55 illustrates a top-down view of a forward frame assembly with steering column bracket, according to some embodiments.

FIG. 56A illustrates a top perspective view of a steering column bracket, according to some embodiments.

FIG. 56B illustrates a side perspective view of the steering column bracket of FIG. 56A, according to some embodiment.

FIG. 56C illustrates a rear perspective view of the steering column bracket of FIG. 56A, according to some embodiment

FIG. 57 illustrates a bottom perspective view of an assembly comprising a toe stop, bottom-out protector, running board components, and a body panel, according to some embodiments.

FIG. 58 illustrates a perspective view of a forward frame assembly with the support member associated with the first snowmobile of FIG. 1 superimposed with the support member associated with the second snowmobile of FIG. 8 to illustrate the common connection with the forward frame assembly for each support member.

FIG. 59 illustrates an isometric view of a seat assembly including a fuel tank, a rear panel, and seat frame, according to some embodiments.

FIG. 60 illustrates an isometric view of the seat assembly of FIG. 59 with the seat frame removed, according to some embodiments.

FIG. 61 illustrates a rear view of the rear panel of the seat assembly of FIG. 59, according to some embodiments.

FIG. 62 illustrates a bottom isometric view of the rear panel and the fuel tank of the seat assembly of FIG. 59, according to some embodiments.

FIG. 63 illustrates a top view of the fuel tank of the seat assembly of FIG. 59, according to some embodiments.

FIG. 64 illustrates a bottom view of the fuel tank and the rear panel of the seat assembly of FIG. 59, according to some embodiments.

FIG. 65 illustrates a right side cross-sectional view of the fuel tank, the tunnel, the heat exchanger assembly, and the forward frame assembly, according to some embodiments.

FIG. 66 illustrates a perspective top view of the fuel tank, toe stop, and running board components configured for the first snowmobile of FIG. 1, according to some embodiments.

FIG. 67 illustrates an isometric view of the seat assembly, according to some embodiments.

FIG. 68 illustrates an isometric view of the fuel tank of the seat assembly secured to the tunnel, according to some embodiments.

FIG. 69A illustrates an isometric view of a structural composite taillight housing, according to some embodiments.

FIG. 69B illustrates an isometric view of the structural composite taillight housing of FIG. 69A, according to some embodiments.

FIG. 70A illustrates a left side view of a snowmobile with a snow flap secured to the structural composite taillight housing of FIG. 69A, according to some embodiments.

FIG. 70B illustrates an isometric view of a structural composite taillight housing of FIG. 69A with a mounting point, according to some embodiments.

FIG. 71 illustrates an exploded view of a toe stop and bottom-out protector assembly according to some embodiments.

FIG. 72 illustrates a rear perspective view of a toe stop and bottom-out protector assembly, according to some embodiments.

FIG. 73 illustrates a rear perspective view of a toe stop that may be part of the running board assembly 120A of FIG. 7, according to some embodiments.

FIG. 74 illustrates a perspective view of a toe stop that may be part of the running board assembly 120A of FIG. 7, according to some embodiments.

FIG. 75 illustrates a side perspective view of a toe stop and a bottom out protector that may be part of the running board assembly 120B of FIG. 10, according to some embodiments.

FIG. 76 illustrates a cross-sectional overhead view of a toe stop and body panel configured for the first snowmobile of FIG. 1, with the belt housing assembly removed, according to some embodiments.

FIG. 77A illustrates an isometric view of a right toe stop that may be part of the running board assembly 120A of FIG. 7, according to some embodiments.

FIG. 77B illustrates an isometric view of a right toe stop that may be part of the running board assembly 120A of FIG. 7, according to some embodiments.

FIG. 78A illustrates an isometric view of the rearward facing side of the toe stop of FIGS. 77A and 77B, according to some embodiments.

FIG. 78B illustrates an isometric view the forward facing side of the toe stop of FIGS. 77A and 77B, according to some embodiments.

FIG. 79A illustrates an isometric view from above the toe stop of FIGS. 77A and 77B, according to some embodiments.

FIG. 79B illustrates an isometric view from below the toe stop of FIGS. 77A and 77B, according to some embodiments.

FIG. 80A illustrates an isometric view of an inboard side of the toe stop of FIGS. 77A and 77B, according to some embodiments.

FIG. 80B illustrates an isometric view of the inboard side of the toe stop of FIGS. 77A and 77B, according to some embodiments.

FIG. 81A illustrates an isometric view of an outboard side of a left toe stop that may be part of the running board assembly 120A of FIG. 7, according to some embodiments.

FIG. 81B illustrates an isometric view of an inboard side of a left toe stop that may be part of the running board assembly 120A of FIG. 7, according to some embodiments.

FIG. 82A illustrates an isometric view of the outboard side of the left side toe stop of FIGS. 81A and 81B, according to some embodiments.

FIG. 82B illustrates an isometric view of the inboard side of the left side toe stop of FIGS. 81A and 81B, according to some embodiments.

FIG. 83A illustrates an isometric view of the rearward facing side of the left side toe stop of FIGS. 81A and 81B, according to some embodiments.

FIG. 83B illustrates an isometric view of the forward facing side of the left side toe stop of FIGS. 81A and 81B, according to some embodiments.

FIG. 84A illustrates an isometric view from above the left side toe stop of FIGS. 81A and 81B, according to some embodiments.

FIG. 84B illustrates an isometric view from below the left side toe stop of FIGS. 81A and 81B, according to some embodiments.

FIG. 85A illustrates a view of the right side toe stop of FIGS. 77A and 77B installed as part of the running board assembly 120A, according to some embodiments.

FIG. 85B illustrates a view of the left side toe stop of FIGS. 81A and 81B installed as part of the running board assembly 120A, according to some embodiments.

FIG. 86A illustrates a view of the forward facing surface of the right side toe stop of FIGS. 77A and 77B installed as part of the running board assembly 120A, according to some embodiments.

FIG. 86B illustrates a bottom view of the right side toe stop of FIGS. 77A and 77B installed as part of the running board assembly 120A, with the bottom-out protector installed, according to some embodiments.

FIG. 87A illustrates a bottom view of the left side toe stop of FIGS. 81A and 81B installed as part of the running board assembly 120A, with the bottom-out protector installed, according to some embodiments.

FIG. 87B illustrates a bottom view of the left side toe stop of FIGS. 81A and 81B installed as part of the running board assembly 120A, without the bottom-out protector, according to some embodiments.

FIG. 88A illustrates an isometric view of the left side toe stop of FIGS. 81A and 81B installed as part of the running board assembly 120A, without the bottom-out protector, according to some embodiments.

FIG. 88B illustrates left side view of the left side toe stop of FIGS. 81A and 81B installed as part of the running board assembly 120A, according to some embodiments.

FIG. 89 illustrates the forward facing surface of the left side toe stop of FIGS. 81A and 81B installed as part of the running board assembly 120A, according to some embodiments.

FIG. 90A illustrates a left side view of a right toe stop that may be part of the running board assembly 120B of FIG. 10, according to some embodiments.

FIG. 90B illustrates a perspective view of an inboard side of the right toe stop of FIG. 90A that may be part of the running board assembly 120B of FIG. 10, according to some embodiments.

FIG. 91A illustrates a perspective view of the outboard side of the right side toe stop of FIGS. 90A and 90B, according to some embodiments.

FIG. 91B illustrates a perspective view of the inboard side of the right toe stop of FIGS. 90A and 90B, according to some embodiments.

FIG. 92A illustrates a rear view of the rearward facing side of the toe stop of FIGS. 90A and 90B, according to some embodiments.

FIG. 92B illustrates a front view of the forward facing side of the toe stop of FIGS. 90A and 90B, according to some embodiments.

FIG. 93A illustrates a top view of the toe stop of FIGS. 90A and 90B, according to some embodiments.

FIG. 93B illustrates a bottom view of the toe stop of FIGS. 90A and 90B, according to some embodiments.

FIG. 94A illustrates a perspective view of an outboard side of a left side toe stop that may be part of the running board assembly 120B of FIG. 10, according to some embodiments.

FIG. 94B illustrates a perspective view of an inboard side of the left toe stop of FIG. 94A that may be part of the running board assembly 120B of FIG. 10, according to some embodiments.

FIG. 95A illustrates an isometric view of the outboard side of the left side toe stop of FIGS. 94A and 94B, according to some embodiments.

FIG. 95B illustrates an isometric view of the inboard side of the left side toe stop of FIGS. 94A and 94B, according to some embodiments.

FIG. 96A illustrates a rear view of the rearward facing side of the toe stop of FIGS. 94A and 94B, according to some embodiments.

FIG. 96B illustrates a front view of the forward facing side of the toe stop of FIGS. 94A and 94B, according to some embodiments.

FIG. 97A illustrates a top view of the toe stop of FIGS. 94A and 94B, according to some embodiments.

FIG. 97B illustrates a bottom view of the toe stop of FIGS. 94A and 94B, according to some embodiments.

FIG. 98A illustrates an isometric view of the right side toe stop of FIGS. 90A and 90B installed as part of the running board assembly 120B, according to some embodiments.

FIG. 98B illustrates an isometric view of the left side toe stop of FIGS. 94A and 94B installed as part of the running board assembly 120B, according to some embodiments.

FIG. 99A illustrates a front view of the forward facing surface of the right side toe stop of FIGS. 90A and 90B installed as part of the running board assembly 120B, without the bottom-out protector, according to some embodiments.

FIG. 99B illustrates a bottom view of the right side toe stop of FIGS. 90A and 90B installed as part of the running board assembly 120B, without the bottom-out protector, according to some embodiments.

FIG. 100A illustrates a front view of the left side toe stop of FIGS. 94A and 94B installed as part of the running board assembly 120B, with the bottom-out protector, according to some embodiments.

FIG. 100B illustrates an isometric view of the left side toe stop of FIGS. 94A and 94B installed as part of the running board assembly 120B, according to some embodiments.

FIG. 101 illustrates a bottom isometric view of the left side toe stop of FIGS. 94A and 94B installed as part of the running board assembly 120B, without the bottom-out protector, according to some embodiments.

DETAILED DESCRIPTION

Embodiments of the present disclosure describe one or more components of a running board assembly, a toe stop, a bottom-out protector, and an accessory skid plate assembly, and combinations thereof, that can be removably secured to one or more vehicles, such as snowmobiles 100. The snowmobiles 100 are generally shown in FIGS. 1-10 and may include a chassis 102, a tunnel 104, a motor or engine 106 (hereinafter referred to as “the engine 106”) attached to the chassis 102 and disposed within an engine bay 108, a drive track 110 disposed within the tunnel 104, and a drivetrain 112 configured to provide motive power from the engine 106 to the drive track 110. The snowmobile 100 further includes one or more skis 114 operably connected to handlebars 116 that are used to turn the snowmobile 100 and a seat 118 for the snowmobile driver/passenger.

As shown in FIGS. 11-26B, a running board assembly 120 may include a support member 122 and a running board or foot support member 124 (hereinafter referred to as “the foot support member 124”). The support member 122 may be a tube, may be hollow, and may be comprised of a metal, a metal alloy, a polymeric material, or a fiber reinforced polymer composite. In a non-limiting example, the support member 122 is a steel tube. The rearward end of the support member 122 is removably securable to the tunnel 104, or to a support bracket 184 that is secured to an interior surface of a side panel 182 of the tunnel 104 by a first plurality of screws or threaded fasteners 126. As shown in FIGS. 8 and 11, the rearward end of the support member 122 may extend downwardly from an outboard side 127 of the foot support member 124 and inward to where it is removably attached to a rearward portion 191 of the support bracket 184 that extends below the adjacent portion of the tunnel side panel 182. As shown in FIGS. 5, 8, 70A and 70B, the rearward portion 191 may also provide a common mounting point for a rear suspension component 192 positioned in or below the tunnel 104. In a non-limiting example, a fastener 123 may be inserted through an aperture 194 in the support member 122 and an aperture 193 in the rearward portion 191 to secure the support member 122 to an outward facing surface of the rearward portion 191, and into an aperture in the rear suspension component 192 to secure the rear suspension component 192 to an inward facing surface of the rearward portion 191. In an illustrative example, the rear suspension component 192 may be an upper horizontal member of a rear idler arm that is connected to a rear arm of a rear suspension on a skid frame assembly, or a component operably coupled thereto. An example of such an upper horizonal member is shown in U.S. Pat. No. 9,771,130, entitled “Snowmobile Skid Frame Assembly”, the contents of which are hereby incorporated by reference in its entirety. A forward end 632 of the support member 122 may be removably secured to the snowmobile by, for example, inserting within a tubular rearward leg 326/338 of a forward frame 312 and securing the two tubes together with a removable fastener 125 as best shown in FIGS. 28 and 29. It is also to be understood that the end of the rearward leg 326/338 may be inserted in the forward end of the support member 122 to secure the two together. The forward frame 312 may be the forward frame assembly described in U.S. Provisional Patent Application No. 63/344,165 filed on May 20, 2022, and entitled “Snowmobile Frame,” the contents of which are incorporated by reference in its entirety. The forward end 632 of the support member 122 extends outward, forward, and downward from the rearward leg 326 and transitions into a rearward extending portion that provides an outboard support platform for the foot support member 124. This provides a continuous tubular member comprised of the support member 122 and the rearward leg 326, 338 of the forward frame 312. The continuous tubular member extends from a steering column mount component 328, shown in FIGS. 41B and 41C, located at the top of the forward frame 312 forward of the tunnel 104 and the track drive shaft 352. One or more fasteners 123, 125 provide a removable attachment of the support member 122 to the snowmobile 100 in case the support member 122 needs to be removed or replaced. For example, removal of the fastener 123 allows the support member 122 to be decoupled from the rearward leg 326 or 338. It is to be understood that the forward end 632 and rearward ends 634 of the support member 122 may be fastened to the tunnel 104, a support bracket 184, and/or forward frame 312 by removeable threaded fasteners, fir tree fasteners, clips, etc. The support member 122 may alternatively be formed integrally with the tunnel 104, the foot support member 124, and/or the forward frame 312.

The foot support member 124 provides a support platform for the rider's feet while mounting and riding the snowmobile 100. In an illustrative example as shown in FIG. 15A, a first rail 600 defines an inboard side 128 of the foot support member 124 that is attached to the tunnel 104 or a mounting surface 186 of the support bracket 184 by a second plurality of screws or threaded fasteners 130. As illustrated in FIGS. 19 and 20, a second rail 605 of the foot support member 124 defines a channel 131 extending along an outboard side 127 of the foot support member 124 that receives the support member 122 therein. The first rail 600 may be positioned a first distance apart from the second rail 605 at the forward end 622 of the foot support member 124, and the first rail 600 may intersect or be positioned a second distance apart from the second rail 605 at a rearward end 624 of the foot support member 124. The second rail 605 may be longer than the first rail 600. As used herein, inboard may refer to a location or direction closer to the longitudinal centerline of the snowmobile and outboard may refer to a location or direction further from the longitudinal centerline of the snowmobile. As best shown in FIGS. 16, 19, 25A and 25B, an interior surface of the channel 131 defines a downward facing opening 615 and has a generally semicircular cross section having a radius that is substantially equal to the radius of an outer surface of the support member 122. The downward facing opening 615 may extend continuously along the length of the channel 131 to allow the support member 122 to be inserted into the channel 131 via the opening 615. The second rail 605 defines a plurality of retaining members including, but not limited to, flexible curved clips 132 extending from an outer side of the channel 131 toward the downward facing opening 615 of the channel 131. The retaining members may be integrally formed with the foot support member 124. A second set of retaining members may be provided, such as clips 133 that are positioned adjacent the cross members 610 and extend from the opposite side of the channel 131 toward the downward facing opening 615 of the channel 131. The clips 132 and 133 may have a radius substantially equal to that of the channel 131. The combination of the channel 131 and the clips 132, and optionally the clips 133, may have a cross section with a circular sector shape having a measurement greater than 1.02π radians and less than 1.5π radians so that the channel 131 and clips 132 (with or without the clips 133) wrap around at least 40% of a circumference of the support member 122, and optionally at least 50% of a circumference of the support member 122, and optionally between 51% and 75% of a circumference of the support member 122. The radius of this circular sector is substantially equal to the radius of an outer surface of the support member 122 and is sized so that the flexible clips 132 apply a compressive force to the support member 122 to removably secure the foot support member 124 to the support member 122. The clips 132 are offset from the clips 133 along the length of the channel 131. Offsetting the clips 132 and 133 along the length of the channel 131 facilitates insertion and removal of the support member 122 in the channel 131 and maintains the strength of the region of the foot support member 124 forming the channel 131. The outboard side 127 of the foot support member 124 may be retained to the support member 122 solely by the clips 132 and 133 to allow the support member to be inserted in or removed from the channel 131 without tools. However, it is to be understood that fasteners may be driven through the foot support member 124 and the support member 122 to removably secure the foot support member 124 to the outboard side of the support member 122. In a non-limiting example, fasteners may be used in combination with the clips 132 and 133 to secure the foot support member 124 to the support member 122.

In some examples, the foot support member 124 is formed of a polymeric material. Illustrative polymeric materials may include, but are not limited to, a polyamide, e.g., NYLON 6/6 OR NYLON 12. In other non-limiting examples, such a polymeric material includes, but is not limited to, polyetheretherketone (PEEK), polypropylene (PP), polyphthalamide (PPA) and/or polybutylene terephthalate (PBT). In some examples, the foot support member 124 may be formed of a composite of a polymer and other materials. For example, the foot support member 124 may comprise a composite including one or more of the above-described polymers and one or more types of reinforcements including, but not limited to, glass and/or carbon fibers, e.g., 30 wt % glass filled polyamide. In a non-limiting example, the fiber % by weight of the composite material may range from 10 wt % to 50 wt %, and may optionally be in the range of 20 wt % to 60 wt %, or optionally in the range of 45 wt % to 55 wt %. In some embodiments, the foot support member 124 includes polymeric material including, but not limited to, Nylon 6/6, Polyetheretherketone (PEEK), Polypropylene (PP), or Polyphthalamide (PPA) as a matrix material with glass, carbon, or ratio of both carbon and fiber material for fiber fill varying in percent volume from 10%-50%, optionally from 40%-60%, and in some embodiments, from 45%-55%. These materials have the advantages of being tough enough to withstand impacts while also being flexible enough to form the flexible clips 132 and 133 so that the flexible clips 132 and 133 may be integrally formed with the foot support member 124. The polymeric composite materials may comprise a thermal conductivity that is less than 10 W/m-° K, and optionally less than 5 W/m-° K, and optionally less than 1 W/m-° K. This thermal conductivity may provide the benefit of reducing conductive heat loss through a rider's boot from contact with the foot support member 124.

The support member 122 and the foot support member 124 are removably attached to the tunnel 104 or to a support bracket 184 that is secured to a side panel 182 of the tunnel 104. The foot support member 124 is removably secured to the support member 122, thereby allowing these components to be separately replaced.

As shown in FIGS. 15A, 21A-21B, and 23A-23B, the foot support member 124 includes a first rail 600, a second rail 605 that at least partially defines the channel 131, and plurality of cross members 610 extending between the first rail 600 and the second rail 605. The cross members 610 partially define a plurality of apertures 134 extending from the first rail 600 to the second rail 605. These apertures 134 are configured to shed snow or other debris through the cross members 610 of the foot support member 124 and may reduce the weight of the snowmobile and/or the material needed to form the foot support member 124. The foot support member 124 may define a plurality of ridges 136 that extending from a top surface 138 of the cross members and optionally along the first rail 600. At least some of the ridges 136 are located intermediate at least some of the apertures 134. The ridges 136 are configured to enhance traction of a rider's boot with the foot support member 124. As shown in FIG. 17, the ridges 136 may be notched or serrated to further enhance traction. As best shown in FIG. 16, the inclusion of a series of ridges 136 inboard of the cross members 610 along the first rail 600 provides additional surface area for boot traction when at least a portion of the forward end of the foot support member 124 is positioned further outboard from the tunnel 104 in a first configuration (running board assembly 120A) as shown in FIG. 3 than a second configuration (running board assembly 120B) as shown in FIG. 10. In an illustrative example, the running board assembly 120A may include a first support tube 122A (FIG. 58) and a first support bracket 184A (FIG. 37A-B), and the running board assembly 120B may include a second support tube 122B (FIG. 37C-D) that is different than the first support tube 122A, and a second support bracket 184B that is different than the first support bracket 184A. Although the support tubes 122A, 122B and the support brackets 184A, 184B are different, each are still compatible with and can be removable secured to the common foot support member 124. Accordingly, the same foot support member 124 can be used on different snowmobile configurations or models that arrange the foot support member 124 in a different configuration or position with respect to the tunnel 104. The series of ridges 136 positioned along the first rail 600 may have a base or a crown that is positioned lower than a corresponding base or crown of the ridges 136 on the cross members 610, and the base or crown of ridges 136 positioned along the second rail 605 be positioned higher than the corresponding base or crown of the ridges 136 on the cross members 610.

In an embodiment as shown in FIGS. 26-31, toe stops 140 are provided. In an illustrative example, the toe stops 140 may be removably securable to one or more of the foot support member 124, the forward frame assembly 312, and the tunnel 104 by screws or threaded fasteners 142. The toe stops 140 may be configured to receive at least a portion of the rider's boots. The front toe stops 140 are positionable at the front end of the running board assembly 120 and may be at least partially disposed within or positioned adjacent to a front cowl or body panel 400 of the snowmobile forming the engine bay 108. As shown in FIG. 26, the front toe stops 140 define a plurality of openings 144 that are in fluid communication with the engine bay 108 and are configured to exhaust air warmed by the engine 106 from inside the engine bay 108. These openings 144 may transfer heat from inside the engine bay 108 and direct it toward the toe pocket 222. The front toe stops 140 may include one or more features to receive and optionally secure the support member 122 thereto. The support member 122 may define a substantially U-shaped configuration along the outboard side 127 of the foot support member 124 with an open end facing rearwardly to accommodate the transition between the toe stops 140 and the foot support member 124. The front toe stops 140 may comprise a polymeric composite material, optionally the same material used to form the foot support member 124. For example, the toe stop 140 may comprise a composite including one or more of the above-described polymers and one or more types of reinforcements including, but not limited to, glass and/or carbon fibers, e.g., 30 wt % glass filled polyamide. In a non-limiting example, the fiber % by weight of the composite material may range from 10 wt % to 50 wt %, and may optionally be in the range of 20 wt % to 60 wt %, or optionally in the range of 45 wt % to 55 wt %. In some embodiments, the toe stop 140 includes polymeric material including, but not limited to, Nylon 6/6, Polyetheretherketone (PEEK), Polypropylene (PP), or Polyphthalamide (PPA) as a matrix material with glass, carbon, or ratio of both carbon and fiber material for fiber fill varying in percent volume from 10%-50%, optionally from 40%-60%, and in some embodiments, from 45%-55%.

In an embodiment as shown in FIGS. 32-37, a rear kick-up panel 146 is provided. In an illustrative example, the rear kick-up panel 146 extends from the foot support member 122 along a transition length 105 of the tunnel 104 to a part of the bumper assembly, such as an arm 525. In addition to, or alternatively, the rear kick-up panel 146 is supported by the support member 122 on the forward outboard end of the rear kick-up panel 146. The rear kick-up panel 146 may be removably secured to one or more of the rearward end of the foot support member 124, the support bracket 184, the rear bumper 530, and the side panel 182 of the tunnel 104. In a non-limiting example, the rear kick-up panel 146 includes a first rail 500, a second rail 505, and one or more cross members 510 extending between the first rail 500 and the second rail 505. The forward end 147 of the rear kick-up panel 146 may overlap a rearward end of the foot support member 124, and the rear kick-up panel 146 may define one or more apertures 555 that may receive a fastener (e.g., fastener 553 in FIG. 44) to maintain positioning of the foot support member 124 and the rear kick-up panels 146. In an illustrative example as shown in FIGS. 35A and 35C, the foot support member 124 may define one or more slots 557 that are alignable with the apertures 555 in the rear kick-up panel 146. Although the position of the rear kick-up panel 146 may be fixed with respect to the tunnel 104, the slots allow the foot support member 124 to be fastened to the rear kick-up panel 146 in either of the running board assembly positions 120A or 120B. As shown in FIG. 35A, the apertures 555 are located near a rearward end of the slots when in the running board assembly 120A configuration is desired. As shown in FIG. 35C, the apertures are located near a forward end of the slots when the running board assembly 120B configuration is desired. As shown in FIG. 44, a self-tapping (and removable) fastener may be inserted from the bottom of the foot support member 124 through the slot and into the apertures 555 to secure the foot support member 124 to the rear kick-up panel 146. Accordingly, the slots allow for the same foot support member 124 and the same kick-up panel 146 to be used on both running board assembly 120A-B configurations, thereby reducing inefficiencies associated with the production of different components specific to a particular configuration. Although the slots are included on the foot support member 124 and the apertures 555 are included on the rear kick-up panels 146, it is to be understood that the rear kick-up panels 146 could include the slots and the foot support member 124 could include the apertures 555. It is also to be understood that the present disclosure is not limited to a slot and aperture system for allowing the foot support member 124 to be selectively positioned in different configurations with respect to the tunnel 104 and/or the rear kick-up panel 146. As shown in FIGS. 33 and 36, the second rail 505 may define a channel 149 at the forward end 147 that is positioned adjacent the foot support member 124 and is shaped to receive a portion of the support member 122 therein. The first rail 500 and the second rail 505 may extend from the forward end 147 and converge at a rearward end 515 to define a member 520 extending therefrom. As shown in FIG. 17, the member 520 is removably securable to, for example, the side panel 182 of the tunnel 104 and/or an arm 525 extending from the rear bumper 530. In a non-limiting example, the arm 525 may be a hollow member. The member 520 may an upper wall 522 that is positionable on top of an upper surface of the arm 525 to support the rear kick-up panel 146 thereon. An outboard wall 524 of the member 520 overlaps an outboard wall 526 of the arm 525 and defines an aperture for receiving a threaded fastener 535 therethrough. The threaded fastener 535 may be inserted through coaxially aligned apertures on the member 520 and the arm 525 to removably secure the kick-up panel 146 to the rear bumper 530 with, for example, a clip nut 550 positioned on an underside of the member 520 and the arm 525 when installed thereon. The member 520 is optionally removably secured to the side panel 182. As shown in FIG. 36, a flange 540 extends downward from the first rail 500 and is positioned adjacent an edge of a transitional length of the side panel 182 of the tunnel 104, and is removably secured thereto with threaded fasteners 544 inserted from the inner surface of the side panel 182 through apertures 227, that optionally also extend through the body 185 of the support bracket 184 through apertures 188 (as shown in FIG. 37B and 37D), and outward through the flange 540 and removably secured with nuts 545. The rear kick-up panels 146 may comprise a polymeric composite material, optionally the same material used to form the foot support member 124. The rear kick-up panels 146 may also define apertures 134 and ridges 136 similar to those of the foot support member 124 as t shown in FIGS. 34A and 34B.

In an embodiment, bottom-out protectors 148 may be provided. In an illustrative example as shown in FIGS. 13, 27B, and 30, the bottom-out protectors may project from a portion of the chassis 102 and are configured to inhibit the transmission of forces directly to the chassis 102. The bottom-out protectors 148 are positioned on the chassis 102 in a location lower than the foot support member 124. In a non-limiting example, the bottom-out protectors 148 are positioned at least partially outboard of the tunnel 104, and at least partially inboard of the support member 122 of the running board assembly. The bottom-out protectors 148 may be positioned to contact a ground-based obstacle before another part of the chassis 102. The bottom-out protectors 148 are formed from a resilient material, such as, for example, an unfilled thermoplastic olefin material. In some embodiments, the bottom-out protector 148 may be formed of a fiber reinforced polymer material including one or more of the above-described polymers and one or more types of reinforcements including, but not limited to, glass and/or carbon fibers, e.g., 30 wt % glass filled polyamide. In a non-limiting example, the fiber % by weight of the composite material may range from 20 wt % to 60 wt %, and may optionally be in the range of 20 wt % to 40 wt %, or optionally in the range of 25 wt % to 35 wt %. In some embodiments, the bottom-out protector 148 includes polymeric material including, but not limited to, Nylon 6/6, Polyetheretherketone (PEEK), Polypropylene (PP), or Polyphthalamide (PPA) as a matrix material with glass, carbon, or ratio of both carbon and fiber material for fiber fill varying in percent volume from 10%-50%, optionally from 40%-60%, and in some embodiments, from 45%-55%.

As shown in FIGS. 37A and 37B, the support bracket 184 is provided with a body 185 that includes a plurality of apertures 188 for receiving the fasteners 126 to secure the support bracket 184 to an interior surface of the side panel 182. As shown in FIGS. 37A and 43, the support bracket includes an upper flange 189 that is positionable along the underside of the center plate 180 and extends toward a centerline of the tunnel 104. The upper flange 189 is provided with a plurality of apertures 190 for receiving fasteners therethrough to secure the upper flange 189 to the underside of the center plate 180. As shown in FIG. 40C, the tunnel 104 comprises a lower end, the lower end including a first length 103, a transition length 105, and a second length 107 extending to a rear end 109 (i.e., a second end) of the tunnel 104. The support bracket 184 may be configured to extend from the first length 103 to the second length 107 along the transition length 105. In some embodiments, the first length 103 and the second length 107 may be substantially parallel, with the transition length 105 oriented non-parallel to the first length 103 and the second length 107. In some embodiments, the first length 103 and the second length 107 may be substantially parallel to the top surface of the tunnel 104. In some embodiments, the bumper arm 525 may be positioned along the second length 107 of the side panel 182.

The tunnel 104 of the snowmobile 100 may also include a center plate 180 and a first and second side panel 182. The first side panel 182 includes a first end that is connected to the center plate 180 and a second, or free, end extending away from the center plate 180. The second side panel 182 also includes a first end that is connected to the center plate 180 and a second end that extends from the center plate 180. As shown in FIG. 43, a first support bracket 184 is secured to an interior surface of the first side panel 182, and a second support bracket 184 is secured to an interior surface of the second side panel 182. In a non-limiting example, the support brackets 184 may extend along one or more lengths of the free end of the side panels 182 of the tunnel 104. The free end of the side panels 182 may comprise a first length, a second length positioned rearward from the first length, and a transition length extending from the first length to the second length. The support bracket 184 may be positioned along at least a portion of one or more of the first length, the second length, and the transition length. The portion of the support bracket 184 positioned along the first length may be secured to the foot support member 124, the portion of the support bracket 184 positioned along the transition length may be secured to the rear kick-up panel 146, and the portion of the support bracket 184 positioned along the second length may be secured to a portion of the bumper 530. Accordingly, the support bracket 184 can reinforce the tunnel 104 to support components positioned outboard thereof. Each support bracket 184 may include a mounting surface 186 extending underneath the second ends of the side panels 182 and outboard from the side panel 182 that the foot support members 124 are removably secured to. The mounting surface 186 may be provided with one or more projections 195 extending outward, and the apertures 187 may be provided on the projections 195. The apertures 187 for receiving the fasteners 130 for securing the foot support members 124 to the mounting surface 186 may each be positioned at the same distance from the longitudinal centerline of the tunnel 104 as utilized in the running board assembly 120B configuration. Optionally, one or more of the apertures 187 may be positioned at a greater distance from the longitudinal centerline of the tunnel 104 than the other apertures 187, as utilized in the running board assembly 120A configuration.

As shown in FIGS. 44 and 45, the inboard side of the foot support members 124 may be positioned on top of the mounting surfaces 186 and the fasteners 130 used to secure the foot support member 124 may be inserted through the apertures 187 in the support bracket 184 and threaded into the foot support member 124. The fasteners may be inserted into the first rail 600, the cross member 610, or an area positioned at the intersection of the first rail 600 and the cross member 610.

As explained above, the foot support member 124 may be positioned in different configurations with respect to one or both of the chassis 102 and tunnel 104 by modifying one or both of the support member 122 and the support bracket 184. As shown in FIG. 37A, the support bracket 184 is provided with a series of the apertures 187 for receiving fasteners 130 for removably securing the foot support member 124 thereto. In a first configuration (running board assembly 120A) as shown in FIGS. 7, 37A and 87B, the apertures 187 on the mounting surface 186 are positioned along a line that extends progressively outward from the body 185 of the support bracket 184 and the adjacent side panel 182. In a second configuration as shown in FIGS. 10, 12, 37C and 101, the apertures 187 on the mounting surface 186 may be positioned the same distance from the body 185 of the support bracket 184, so that the apertures 187 are positioned along a line parallel to the adjacent side panel 182. The distance that the forward end of the support member 122 extends outward from the rearward leg 326 and the sides of the snowmobile 100 can be increased or decreased to accommodate the differences between the first and second configurations. Accordingly, the same foot support member 124 can be applied to different snowmobile configurations or models without modification of the foot support member 124, simply by using a support bracket 184 with a different mounting surface 186 configuration. It is to be understood, however, that different support members could be used with the different support brackets. As shown in FIG. 58, different support members 122A, 122B may be provided to accommodate the different orientation of the foot support member 124 due to the use of different support brackets 184. When the support bracket 184 shown in FIG. 37A is used, the support tube 122A is used and it extends further outboard than the support tube 122B used when the support bracket 184 shown in FIG. 37C is used. The rear end of the support tubes 122A, 122B are secured to either the side panel 184 of the tunnel 104 and/or the support bracket 184. The rear end of the support tubes 122A, 122B may be secured in the same location on the different snowmobiles, or at different positions. For example, the support tube 122A may be connected to a first rear suspension, and the support tube 122B may be connected to a second rear suspension that is different than the first rear suspension.

In a non-limiting example, the support bracket 184 may be used to provide targeted reinforcement to portions of the tunnel 104, thereby allowing the tunnel 104 to be made of a thinner and lighter gauge of sheet metal or a fiber reinforced polymer. In a non-limiting example, the first side panel 182 comprises a sheet metal or metal alloy that has a first thickness and the first support bracket 184 comprises a sheet metal or metal alloy that has a second thickness that is different than, and optionally greater than the first thickness. In addition to, or alternatively, the tunnel 104 may be comprised of a first material, e.g., aluminum or an aluminum alloy, and the first support bracket 184 may be comprised of a second material, such as steel, that is different than the first material and has a higher value of Young's modulus. It is to be understood, however, that the support bracket 184 may be comprised of the same material as the tunnel 104.

With respect to the foot support member 124, the second rail 605 may define a plurality of openings 675 from the top surface 138 to the channel 131 that extend along an outboard side of the second rail 605 and face outwardly from the tunnel 104. Optionally, the second rail 605 may define a second plurality of openings 680 from the top surface 138 to the channel 131 that extend along an inboard side of the second rail 605 and face inwardly toward the tunnel 104. The openings 680 may be offset from the openings 675 along the length of the channel 131. One or more ridges 136 may at least partially define the outer perimeter of the openings 675, and optionally the outer perimeter of the openings 680. As shown in FIG. 25A, the clips 132 may be positioned along the second rail 605 below the openings 675 and extend downward and inward toward the downward facing opening 615. As shown in FIG. 25B, the clips 133 may be positioned along the second rail 605 below the openings 680 and extend downward from the bottom surface 139 of the foot support member 124 and outward towards the downward facing opening 615. The clips 133 may be at least partially positioned along a leading edge 617 of the cross members 610 and extend outward therefrom toward the downward facing opening 615.

While the running board and running board assembly presented herein is employed on a snowmobile, different embodiments of the running board and running board assembly may be applied to other types of vehicles, such as a snow bike or a personal off-road vehicle.

FIG. 39 shows a illustrative method 200 of assembling a snowmobile that includes a chassis 102, an engine 106 attached to the chassis and disposed within an engine bay 108, a drive track 110, a drivetrain 112 operatively interconnecting the engine with the drive track 110 and configured to deliver propulsive power to the drive track 110, a tunnel 104 attached to the chassis 102, and a running board assembly 120 attached to the tunnel 104. The method 200 includes the following steps:

STEP 202, ATTACH A SUPPORT MEMBER, includes attaching a support member 122 to one or more of the forward frame assembly 312, the tunnel 104 and the support bracket 184 to position the support member 122 outboard of the tunnel 104;

STEP 204, ATTACH INBOARD SIDES OF A FOOT SUPPORT MEMBER, includes attaching inboard sides 128 of a foot support member 124 to the tunnel 104 and/or the support bracket 184 using a plurality of threaded fasteners 130;

STEP 206, ATTACH THE FOOT SUPPORT MEMBER TO THE SUPPORT MEMBER, includes retaining outboard sides 127 of the foot support member 124 to the support member 122 optionally using a plurality of flexible clips 132 that are integrally formed with the foot support member 124 and are defined on an outboard edge of the foot support member 124. Each of the flexible clips 132 wraps around at least 51% and at most 75% of a circumference of the support member 122. The flexible clips 132 are sized to apply a compressive force to the support member 122;

STEP 208, ATTACH FRONT TOE STOPS, includes attaching front toe stops 140 to one or more of the foot support member 124, the support member 122, the tunnel 104, body panels 400, 402, and the forward frame assembly 312;

STEP 210, ATTACH REAR KICK-UP PANELS, includes attaching rear kick-up panels 146 to one or more of the bumper 530, the support bracket 184, the foot support member 124, the support member 122, and the tunnel 104; and

STEP 212, ATTACH BOTTOM-OUT PROTECTORS, includes attaching bottom-out protectors 148 to one or more of the tunnel 104, the heat exchanger end cap 178, the forward frame assembly 312, the foot support member 124, the toe stop 140, and body panels 400, 402. The bottom-out protectors 148 may be formed of an unfilled thermoplastic olefin material or a thermoplastic polyurethane material. The bottom-out protectors 148 may be located outboard of at least a portion of the tunnel 104 and inboard of at least a portion of the support member 122, wherein the bottom-out protectors 148 are positioned on the chassis 102 in a location that is lower, i.e., closer to the ground, than the tunnel 104 and the foot support member 124. It is to be understood that steps 202, 204, 206, 208, 210 and 212 may be performed in any order, and that one or more of the steps may be optional.

As illustrated in a non-limiting example of FIGS. 40A-42D, the snowmobile 100 may include a forward frame assembly 312 including a plurality of tube members. The forward frame assembly 312 may be assembled prior to securing to one or both the tunnel 104 and heat exchanger assembly 174. The forward frame assembly 312 may define a front, a rear, and a longitudinal centerline. The forward frame assembly 312 may include a first side 304 extending substantially along the longitudinal centerline and a second side 306 extending substantially along the longitudinal centerline and spaced apart from the first side 304. Each of the first side 304 and the second side 306 includes an inner perimeter 308 defining a side opening 310. The first side 304 and the second side 306 are positioned to define a rear opening 314 therebetween at the rear of the forward frame assembly 312 for receiving the heat exchanger assembly 174, tunnel 104, or both therein.

According to one or more aspects of the present disclosure, a forward frame assembly 312 for a snowmobile 100 is provided including a front, a rear, and a longitudinal centerline extending from front to rear. The forward frame 312 includes a first side 304 extending along the longitudinal centerline, a second side 306 extending along the longitudinal centerline and spaced apart from the first side 304. Each of the first side 304 and the second side 306 includes an inner perimeter 308 defining a side opening 310. The first side 304 and the second side 306 define a rear opening 314 therebetween at the rear of the forward frame 312 for receiving a heat exchanger assembly 174 and/or tunnel 104 therein.

Optionally, the first side 304 defines an outer perimeter 318, the second side 306 defines an outer perimeter 318, and a track drive shaft 352 extends across the forward frame assembly 312. The track drive shaft 352 is positioned rearward of the outer perimeter 318 of the first side 304 and forward of the outer perimeter 318 of the second side 306.

Optionally, the track drive shaft 352 is positioned rearward of the inner perimeter 308 of the first side 304 and rearward of the inner perimeter 308 of the second side 306.

Optionally, the second side 306 includes a metal plate or sheet 320 (hereinafter referred to as “the metal sheet 320”) defining an aperture 322 for receiving the track drive shaft 352 therethrough when the metal sheet 320 is positioned to overlap a heat exchanger end cap 178 of the heat exchanger assembly 174 or a side of the tunnel 104.

Optionally, the metal sheet 320 of the second side 306 defines a first aperture 324 therein for receiving the track drive shaft 352 in a first position or a second position that is different than the first position.

Optionally, the second side 306 includes a rearward leg 326, such as a hollow tube, extending upward and forward from the metal sheet 320 to a steering column mount component 328, a forward leg 330, such as a hollow tube, extending upward and rearward to the steering column mount component 328, and a horizontal member 331 (shown in FIGS. 12 and 41A) substantially extending along the longitudinal centerline from the forward leg 330 to the rearward leg 326. An upper end of the metal sheet 320 is shaped to support a rearward end of the horizontal member 331 and is removably secured thereto, and the rearward end of the horizontal member 331 is vertically positioned higher than the front end of the tunnel 104.

Optionally, the steering column mount component 328 may be configured to secured to the forward legs 330 and the rearward legs 326 (see e.g., FIGS. 55-56C). The steering column mount component 328 may include one or more mounting points 333 configured to secured to a steering column.

Optionally, the first side 304 includes a metal plate or sheet 334 (hereinafter referred to as “the metal sheet 334”) defining an aperture for securing a belt housing assembly 354 thereto when the metal sheet 334 is positioned to overlap the heat exchanger end cap 178 of the heat exchanger assembly 174 and/or a side panel 182 of the tunnel 104.

Optionally, the metal sheet 334 of the first side 304 defines a first aperture therein for securing the belt housing assembly 354 in a first position as shown in FIG. 42A or a second position as shown in FIG. 42C that is different than the first position.

Optionally, the first side 304 includes a rearward leg 338 extending upward and forward from the metal sheet 334 to a steering column mount component 328, a forward leg 330 extending upward and rearward to the steering column mount component 328, and a horizontal member 342 substantially extending along the longitudinal centerline from the forward leg 330 to the rearward leg 326, and a rearward end of the horizontal member 342 is vertically positioned higher than the front of the tunnel 104.

Optionally, a jack shaft, as disclosed in U.S. patent application Ser. No. 17/588,487, entitled ADJUSTABLE BELT DRIVE ASSEMBLY, SYSTEM AND METHOD, filed Jan. 31, 2022, which is commonly owned and incorporated herein by reference in its entirety, extends across the forward frame 312 and is positioned beneath the horizontal member 342 of the first side 304.

Optionally, a steering column mount component 328 extends between the first side 304 and the second side 306. The first side 304 and the second side 306 each includes a leg 326, 338 extending upward and forward from the rear of the forward frame 312 to the steering column mount component 328.

Optionally, the steering column mount component 328 includes a first side including a first steering mount 344 that is securable to the steering column assembly shown in FIGS. 41C, 51A and 51B, and a second side that includes a second steering mount 346 that is securable to the steering column assembly shown in FIGS. 41B, 50A and 50B, wherein the second side is positioned rearward of the first side along the longitudinal centerline.

Optionally, the first steering mount 344 is positioned forward along the longitudinal centerline of the forward frame assembly 312, of the heat exchanger assembly 174, and the tunnel 104.

Optionally, the first side 304 includes a rearward tube 338. The rearward tube 338 include a first end extending upward and forward from the metal sheet 334 to a steering column mount component 328, and a second end extending outward from the first side 304. A support member 122 is provided that includes a tube with a first end that is mated with the second end of the first side rearward tube 338 and a second end secured to a rearward portion of the tunnel 104 and/or support bracket 184. The rearward tube 338 of the first side 304 and the tube of the support member 122 define a continuous tubular length extending from the steering column mount component 328 to rearward of the foot support member 124 to a rear suspension component.

According to one or more aspects of the present disclosure, a method of assembling a snowmobile 100 is provided including providing a preassembled forward frame 312 including a front and rear, the forward frame 312 including a first side 304 and a second side 306. The first and second sides 304, 306 are spaced apart from each other to define a rear opening 314 at the rear of the forward frame 312. At least a portion of a heat exchanger assembly 174, a tunnel 104, or both are positioned in the rear opening 314 between the first side 304 and the second side 306. The preassembled forward frame 312 is then secured to the heat exchanger assembly 174, the tunnel 104, or both.

Optionally, each of the first side 304 and the second side 306 includes an inner perimeter 308 defining a side opening 310.

Optionally, the method includes inserting an engine 106 through the side opening 310 of the second side 306 and securing the engine 106 to the forward frame 312.

According to one or more aspects of the present disclosure, a method of assembling two different snowmobiles with a common forward frame, optionally on a common assembly line, is provided including providing a common forward frame, providing a first rear body component or a second rear body component, securing either the first body component or the second body component to the forward frame, and securing a track drive shaft 352 in a first position with respect to the forward frame when the first body component is secured to the forward frame or securing a track drive shaft 352 in a second position with respect to the forward frame when the second body component is secured to the forward frame, wherein the first position is different than the second position. In a non-limiting example, the first body component and the second body component are different tunnels. In a non-limiting example, the first body component and the second body component are different heat exchanger assemblies. In a non-limiting example, the first body component and the second body component are different support members 122. In a non-limiting example, the first body component and the second body component are different steering column assemblies. In a non-limiting example, the first body component and the second body component are different front suspensions. In a non-limiting example, the first body component and the second body component are different steering column assemblies. In a non-limiting example, the first body component and the second body component are different toe stops. In a non-limiting example, the first body component and the second body component are different bottom-out protectors.

Optionally, the method includes securing a belt housing assembly to the forward frame, the belt drive housing defining a track drive shaft opening, wherein the track drive shaft opening is located at a first position with respect to the forward frame when the forward frame is secured to the first rear body component, and wherein the track drive shaft opening is located at a second position with respect to the forward frame when the forward frame is secured to the second rear body component, wherein the first position is different than the second position.

Optionally, the first body component is a tunnel, a heat exchanger assembly component, or both. Optionally, the first body component is a running board assembly. Optionally, the second body component is a tunnel, a heat exchanger assembly, or both. Optionally the second body component is a running board assembly.

According to one or more aspects of the present disclosure, a method of assembling two types of snowmobiles with different drive track requirements is provided including providing a common forward frame, providing a first body component with a first drive track requirement and a second body component with a second drive track requirement that is different than the first drive track requirement, wherein at least a first engine mount is provided on one or more of the forward frame, the first body component, and the second body component, positioning either the first body component or the second body component adjacent the forward frame, and securing a belt housing assembly 354 to the first engine mount, the belt housing assembly 354 defining a track drive opening, wherein the track drive opening is located at a first position with respect to the first engine mount when the forward frame is secured to the first body component, and wherein the track drive opening is located at a second position with respect to the first engine mount when the forward frame is secured to the second body component, wherein the first position is different than the second position.

Optionally, the first body component is a tunnel, a heat exchanger assembly, or both. Optionally the first body component is a running board assembly. Optionally, the second body component is a tunnel, a heat exchanger assembly, or both. Optionally the second body component is a running board assembly.

According to one or more aspects of the present disclosure, a method of assembling two types of snowmobiles with different drive track requirements is provided including providing a common forward frame including a front and rear, the forward frame including a first side, and a second side spaced apart from the first side to define a rear opening at the rear of the forward frame. The method includes providing a first body component with a first drive track shaft position and a second body component with a second drive track shaft position that is different than the first drive track position. The method includes positioning either the first body component or the second body component in the rear opening between the first side and the second side, providing a belt drive housing that defines a track drive shaft opening, securing the belt housing assembly to the first side of the forward frame, wherein the track drive shaft opening is located at a first position with respect to the first side when the forward frame is secured to the first body component, and wherein the track drive shaft opening is located at a second position with respect to the first side when the forward frame is secured to the second body component, wherein the first position is different than the second position.

Optionally, each of the first side and the second side includes an inner perimeter defining a side opening.

Optionally, the belt housing assembly is secured to the first side for both body components with a jackshaft axis extending through the side openings of the first side and the second side, and a track drive shaft axis positioned outside of an outer perimeter of the first side and inside of an outer perimeter of the second side.

Optionally, the method includes inserting an engine through the side opening of the second side and securing the engine to the preassembled frame at a position between the first and second sides.

According to one or more aspects of the present disclosure, a front frame assembly 312 for a snowmobile 100 is provided including a front, a rear, and a longitudinal centerline. The forward frame 312 includes a first side 304 extending along the longitudinal centerline and a second side 306 extending along the longitudinal centerline and spaced apart from the first side 304. Each of the first side 304 and the second side 306 includes an inner perimeter 308 defining a side opening 310. The first side 304 and the second side 306 define a rear opening 314 at the rear of the forward frame 312 therebetween for receiving a heat exchanger assembly 174, a tunnel 104, or both therein.

Optionally, the first side 304 defines an outer perimeter 318, and the second side 306 defines an outer perimeter 318. A track drive shaft 352 extends across the forward frame 312 and is positioned rearward of the outer perimeter 318 of the first side 304 and forward of the outer perimeter 318 of the second side 306.

Optionally, the first side 304 defines an inner perimeter 308, the second side 306 defines an inner perimeter 308, and the track drive shaft 352 is positioned rearward of the inner perimeter 308 of the first side 304 and rearward of the inner perimeter 308 of the second side 306.

Optionally, the second side 306 includes a plate or metal sheet, hereinafter referred to as metal sheet 320, defining an aperture 322 for receiving the track drive shaft 352 therethrough when the metal sheet 320 is positioned to overlap an end cap 178 of the heat exchanger assembly 174, a side panel 182 of the tunnel 104, or both.

Optionally, the aperture of the metal sheet 320 of the second side 306 defines is shaped to receive the track drive shaft 352 in a first position 322 or a second position 324 that is different than the first position.

Optionally, the second side 306 includes a support tube or rearward leg, hereinafter referred to as rearward leg 326, extending upward and forward from the metal sheet 320 to a steering column mount component 328, a support tube or forward leg, hereinafter referred to as forward leg 330, extending upward and rearward to the steering column mount component 328, and a horizontal member 331 substantially extending along the longitudinal centerline from the forward leg 330 to the rearward leg 326. An upper end of the metal sheet 320 is shaped to support a rearward end of the horizontal member 331 and is removably secured thereto, and the rearward end of the horizontal member 331 is vertically positioned higher than a forward end of the tunnel 104.

Optionally, the first side 304 includes a metal sheet or plate, hereinafter referred to as metal sheet 334, defining an aperture for securing a belt housing assembly 354 thereto when the metal sheet 320 is positioned to overlap an end cap 178 of the heat exchanger assembly 174, a side panel 182 of the tunnel 104, or both.

Optionally, the metal sheet 334 of the first side 304 defines a first aperture therein for securing the belt housing assembly 354 in a first position as shown in FIG. 42A, and a second aperture therein for securing the belt housing assembly 354 in a second position as shown in FIG. 42C that is different than the first position.

Optionally, the first side 304 includes a rearward leg 338 extending upward and forward from the metal sheet 334 to a steering column mount component 328, a forward leg 330 extending upward and rearward to the steering column mount component 328, and a horizontal member 342 substantially extending along the longitudinal centerline from the forward leg 330 to the rearward leg 326, and a rearward end of the horizontal member 342 is vertically positioned higher than a forward end of the tunnel 104.

Optionally, a jack shaft extends across the forward frame 312 and is positioned beneath the horizontal member 342 of the first side 304.

Optionally, a steering column mount component 328 extends between the first side 304 and the second side 306, wherein the first side 304 and the second side 306 each includes a leg extending upward and forward from the rear of the forward frame to the steering column mount component.

Optionally, the steering column mount component 328 includes a first side including a first steering mount, and a second side that includes a second steering mount, wherein the second side is positioned rearward of the first side along the longitudinal centerline.

Optionally, the first steering mount is positioned forward along the longitudinal centerline of the heat exchanger and the tunnel.

Optionally, the first side 304 includes a rearward tube 338 including a first end extending upward and forward from the metal sheet 334 to a steering column mount component 328, and a second end extending outward from the first side 304, and further including a support member 122 including a tube with a first end that is mated with the second end of the first side tube and a second end secured to a rearward portion of the tunnel 104 and/or support bracket 184, wherein the rearward tube 338 of the first side and the tube of the support member 122 define a continuous tubular length extending from the steering column mount component 328 to a rear suspension component, and/or rearward of the foot support member 124.

In an embodiment, a method of assembling two different types of snowmobiles with a common forward frame 312 is provided that includes providing a common forward frame 312 including a longitudinal centerline and a support member 122 mounting point 317 positioned outboard of the longitudinal centerline, providing a first running board assembly 120A including a support member 122A; providing a second running board assembly 120B including at least one component that is different than at least one component of the first running board assembly, the second running board assembly 120B including a support member 122B, and securing either the first running board assembly 120A or the second running board assembly 120B to the mounting point 317, wherein the first running board assembly 120B is located at a first position with respect to the longitudinal centerline of the forward frame 312 when secured to the mounting point 317, and wherein the second running board assembly 120B is located at a second position with respect to the longitudinal centerline of the forward frame 312 when secured to the mounting point 317, wherein the first position is different than the second position.

Optionally, each running board assembly includes a foot support member 124, a support member 122, and optionally a support bracket 184. Optionally, the foot support member 124 is a fiber reinforced polymer composite, and the support member 122 is a hollow tube.

Optionally, the mounting point 317 extends outward and forwardly from the forward frame 312. Optionally, the mounting point 317 is positioned below an upper surface of a portion of the tunnel 104 that is secured to the forward frame 312. Optionally, the support member 122 of the first running board assembly 120A extends outward from the centerline of the vehicle farther than the support member 122B of the second running board assembly 120B.

Optionally, the common forward frame 312 includes an A-arm mounting point, and the method may further comprise providing a first suspension assembly (FIGS. 47 and 54) including a control arm and a spindle 492 that includes a lower A-arm ball joint, providing a second suspension assembly (FIGS. 46 and 53) that is different than the first suspension assembly, the second suspension assembly including a control arm and a spindle 490 that includes a lower A-arm ball joint, and securing the A-arm of the first suspension assembly to the A-arm mounting point when the first running board assembly 120A is secured to the mounting point 317 or the second suspension assembly to the A-arm mounting point when the second running board assembly 120B is secured to the mounting point 317, wherein optionally the first lower A-arm ball joint is positioned at a different position with respect to the common forward frame 312 than the second lower A-arm ball joint when the respective suspension assembly is secured to the common forward frame 312. The first suspension assembly may comprise the assemblies disclosed in U.S. Provisional Patent Application No. 63/310,254 filed Feb. 15, 2022, and entitled “Recreational Vehicle Spindle”, U.S. Provisional Patent Application No. 63/404,856 filed Sep. 8, 2022, and entitled “Recreational Vehicle Spindle”, and U.S. patent application Ser. No. 17/982,748 filed on Nov. 8, 2022, and entitled “Recreational Vehicle Spindle,” the contents of each is incorporated by reference in its entirety. The second suspension assembly may comprise the assemblies disclosed in U.S. Provisional Patent Application No. 63/310,276 filed Feb. 15, 2022, and entitled “Spindle for a Recreational Vehicle”, U.S. Provisional Patent Application No. 63/404,841 filed Sep. 8, 2022, and entitled “Spindle for a Recreational Vehicle,” and U.S. patent application Ser. No. 17/988,304 filed on Nov. 16, 2022, and entitled “Spindle for a Recreational Vehicle,” the contents of each is incorporated by reference in its entirety.

Optionally, the support member 122A of the first running board assembly 120A extends outward from the centerline of the vehicle farther than the support member 122B of the second running board assembly 120B, and the lower A-arm ball joint of the first suspension assembly is positioned outward from the centerline of the vehicle a greater distance than the lower A-arm ball joint of the second suspension assembly.

Optionally, wherein the support member 122A of the first running board assembly 120A extends outward from the centerline of the vehicle farther than the support member 122B of the second running board assembly 120B, and the lower A-arm ball joint of the first suspension assembly is positioned farther forward with respect to the common forward frame 312 than the lower A-arm ball joint of the second suspension assembly.

Optionally, wherein the support member 122A of the first running board assembly 120A extends outward from the centerline of the vehicle farther than the support member 122B of the second running board assembly 120B, and the lower A-arm ball joint of the first suspension assembly is positioned along the centerline of the common forward frame 312 farther forward from the mounting point 317 than the lower A-arm ball joint of the second suspension assembly.

In a non-limiting example, different snowmobile models may be assembled using a common forward frame assembly by changing one or more of a spindle, a suspension component such as a control or A-arm, and a steering assembly between models. FIGS. 46 and 47 illustrates a side view of a common forward frame assembly 312 with different suspension components including a second spindle 490 and a first spindle 492, according to some embodiments. FIGS. 48 and 49 show a front view of the two different models utilizing the common forward frame assembly. As shown in FIGS. 49 and 54, the model with the first spindle 492 may have a wider width or stance than the model shown in FIGS. 48 and 53 with the second spindle 490. This difference in width may be configured by providing different control arms for the different models (that extend different distances from the vehicle longitudinal centerline). The location of the spindles 490/492 (and/or at least a portion of the attached skis) may be positioned at different locations along the longitudinal centerline of the vehicle. As shown in FIG. 53, the model may position the second spindle 490 and/or the rearward end of the ski attached to the second spindle 490 farther forward along the longitudinal centerline (and farther forward with respect to the forward frame) than the model with the first spindle 492 and/or the rearward portion of the ski attached to the first spindle 492 (those being positioned further rearward along the longitudinal centerline and further rearward with respect to the forward frame). The height of the two different models may be the same, or different. It is also to be understood that the steering assembly may be the same or different for the different models and may extend forward (FIG. 47) or rearward (FIG. 48) of a steering column bracket (shown in FIGS. 56A, B, C) positioned at the upper portion of the forward frame.

FIGS. 50A-B illustrate side and front views of a steering column assembly used in the assembly of FIGS. 46 and 48, according to some embodiments. FIGS. 51A-B illustrate side and front views of the steering column assembly used in the assembly of FIGS. 47 and 49, according to some embodiments. FIGS. 52A-B illustrate side and front views of the different steering column assemblies superimposed for comparison of the location of the different steering column assemblies when mounted to the forward frame, according to some embodiments. In a non-limiting example, the lower forward end of both steering columns are secured to the same location on the forward frame assembly 312.

FIGS. 53 and 54 illustrate a top-down view of forward frame, suspension, and engine components in a second configuration (FIG. 53) and a first configuration (FIG. 54), according to some embodiments.

FIG. 55 illustrates a top-down view of a forward frame assembly with steering column bracket, according to some embodiments; and FIGS. 56A-C illustrate perspective views of a steering column bracket, according to some embodiments. The steering column bracket may include the one described in U.S. Provisional Patent Application No. 63/344,165 filed on May 20, 2022, and entitled “Snowmobile Frame,” the contents of which are incorporated by reference in its entirety.

FIG. 57 is a view of a polymeric assembly including one or more of the foot support member 124, the toe stop 140, the bottom out protector 148, a rear kick-up panel 146 (not shown) and a body panel 400 or 402. The polymeric assembly may extend from the front of the vehicle to the bumper 530. Optionally, the polymeric assembly comprises one or more components that are positioned outboard of the side panel 182 of the tunnel 104 and extend rearward from the track drive shaft 352 to a point rearward of the fuel tank 650, and optionally to the bumper 530.

FIG. 58 is a side view of two different running board support tubes 122A, 122B used for two different models for comparison purposes. As shown, the one model (high performance) includes the support tube 122A that extends further outboard from the forward frame and is secured to the suspension assembly at a point higher than the support tube 122B for the other model that does not extend outboard as far from the forward frame.

FIGS. 59-68 illustrate a seat support assembly in an illustrative embodiment. The support assembly may include a fuel tank 650 with mounting features 658 for securing a seat or seat frame 652 thereto. A rear panel 656 slidingly engages the fuel tank 650 to define a compartment 668 therebetween that may be used for storage or to house a battery 660 therein. The mounting features 658 may be integral with the fuel tank 650 and may provide a locking feature with the seat frame to provide for more stability both vertically, laterally, and in the forward/rearward directions. The mounting features 658 may be positioned on a raised portion of the fuel tank that may have a triangular shape that is at least partially surrounded by a flat or flangelike surface. A seat fastener feature 662 may be provided on the rear panel 656 for engaging a portion of the seat or the seat frame 652. The underside 664 of the fuel tank 650 may be upwardly recessed along the lower perimeter to slidingly receive extensions 666 of the rear panel 656 therealong so that the extensions 666 of the rear panel 656 are positioned between the underside 664 of the fuel tank 650 and the upper surface of the tunnel. As shown in FIG. 65, a removable accessory mount 181 may be secured to both the tunnel 104 and the support bracket 184. As shown in FIG. 63, the fuel tank 650 may have a convex outer shape and may be almost entirely contained within the rider envelope (all positioned inboard of the upper legs of the front frame member and greater than 95% of the fuel tank volume is positioned inboard of the tunnel side walls, and optionally greater than 97% of the fuel tank volume is positioned inboard of the tunnel side walls, and optionally 99% or greater. The seat assembly may include the one described in U.S. Provisional Patent Application No. 63/350,553 filed on Jun. 9, 2022, and entitled “Snowmobile with Seat and Gas Tank Assembly,” U.S. Provisional Patent Application No. 63/404,682 filed on Sep. 8, 2022, and entitled “Snowmobile with Seat Assembly,” and U.S. patent application Ser. No. 17/988,111 filed on Nov. 16, 2022, and entitled “Fuel Tank and Seat Assembly for a Vehicle,” the contents of each of which are incorporated by reference in its entirety.

FIGS. 69 and 70 show a structural composite taillight housing 700 that is positioned on the upper surface of the rearward end of the tunnel 104. The composite may comprise a polymeric matrix and a fiber reinforcement. The structural composite taillight housing 700 houses the taillight and provides a structural reinforcement on the upper surface of the rearward end of the tunnel 104 that optionally may allow for thinner gauges of tunnel material and may optionally eliminate internal tunnel reinforcements at the rearward end. The structural composite taillight housing 700 also provides a plurality of mounting points 701 for a snow flap 702 that helps to maintain the snow flap position away from the track and rear suspension components. As shown in FIGS. 69 and 70, the ends of the structural composite taillight housing 700 extend around the sides of the rear bumper or grab bar and may engage the outer sides of the snow flap 702. The structural composite taillight housing and the snow flap may include those described in U.S. Provisional Patent Application No. 63/400,056 filed on Aug. 23, 2022, and entitled “Taillight Housing, Snow Flap and Assembly Thereof,” U.S. patent application Ser. No. 17/979,091 filed on November 2, and entitled “Snow Vehicle Heat Exchanger Shield,” and U.S. patent application Ser. No. 17/979,066 filed on Nov. 2, 2022, and entitled “Taillight Housing, Snow Flap and Assembly Thereof,” the contents of each of which are incorporated by reference in its entirety.

As discussed above with reference to FIGS. 26-31, a toe stop 140 is provided. In a non-limiting example, the toe stop 140 may be attached to the foot support member 124 and may be shaped to house a vehicle component and/or receive the rider's foot. Additional views of a toe stop 140 are illustrated in FIGS. 57, 66, and 71-76. A first embodiment of a pair of toe stops 140a/140b with one or more of the features described below is illustrated in FIGS. 74, and 77-89 that is configured for the first snowmobile of FIGS. 1-7 and the first running board assembly 120A. A second embodiment of a pair of toe stops 140c/140d with one or more of the features described below is illustrated in FIGS. 90-101 that is configured for the second snowmobile of FIGS. 8-10 and the second running board assembly 120B. The figures illustrate the toe stop 140 from the front/forward side 10, rear/rearward side 12, the top 14, the bottom 16, the outboard side 127, and the inboard side 128.

In one aspect, the toe stop 140 is a unitary body that can define a toe pocket 222 for receiving the rider's foot. In some implementations, the toe stop 140 is a molded polymeric, and optionally a molded polymeric composite material. In another aspect, the toe stops 140 may be a right (or belt-side) toe stop 140a/140c and a left (or brake-side) toe stop 140b/140d (see e.g., FIG. 66). As discussed below in greater detail, the right and left toe stops 140a/140c, 140b/140d may have different shapes to, for example, accommodate the different composite running board assemblies 120A/120B associated with different snowmobiles. In addition to or alternatively, the toe stop 140 includes one or more features that at least partially house vehicle components including, but not limited to, the belt case assembly or the brake assembly. Thus, parts can be reduced and assembly simplified. In one aspect, the toe stop 140 defines a recess/space to receive one or more internal components. In an aspect, although the toe stops 140a/140c and 140b/140d are shaped differently to, for example, accommodate different vehicle component positions and or running board assemblies on different snowmobiles, the toe stops 140a/140c and 140b/140D may include common mounting features configured to be used, for example, with the common forward frame assembly 312 and any body paneling (such as 400 and 402) that is common between the different snowmobiles 100.

The toe stop 140 may include one or more of the following features: a bottom flange 176 that is engageable with a forward end of the foot support member 124, an outboard wall 197 that is engageable with a body panel 400 and/or 402, a forward wall 163, a toe hook 141, an inboard wall 171/173 that may at least partially house a vehicle component, and a rearward wall 230 that may partially house a vehicle component. The toe stop 140 may be removably secured to one or more components, including, but not limited to, the foot support member 124, the forward frame 312, the bottom-out protector 148, the support member 122, the heat exchanger end cap 178, the body panels 400, 402, and the tunnel 104. For example, the toe stop 140 may be removably secured to mounting features 135/137 of the foot support member 124 (see e.g., FIGS. 21A-B, 31, 87B, 99B, and 101). The toe stop 140 may also be removably secured to mounting features 424/426 of the bottom-out protector 148 (see e.g. FIGS. 27B, 44). Accordingly, the flange portions at the forward end of the foot support member 124 defining the mounting features 135/137 may be positioned between the bottom flange 176 of the toe stop 140 and the mounting features 424/426 of the bottom-out protector 148.

Optionally, the toe stop 140 includes one or more ribs 153/179 (see e.g., FIG. 80A, and 92B). One or more ribs 179 may be located on the forward surface of the forward wall 163. One or more ribs 153 may be located on the inboard surface of inboard wall 171/173 and/or the forward surface of the rearward wall 230. In one aspect, the ribs 153/179 strengthen areas of the walls 163/171/173/230 where openings 144/162/175/231 are located. The toe stop 140 may be removably secured to one or more components, including, but not limited to, the foot support member 124, the forward frame 312, the bottom-out protector 148, the support member 122, the heat exchanger end cap 178, and the tunnel 104.

The bottom flange 176 forms a bottom surface of the toe stop 140. The bottom flange 176 may have a zig-zag configuration (see e.g., FIGS. 79B and 93B). In some implementations, the bottom flange 176 is wider than in other implementations. In some embodiments, the rearward end region of the bottom flange 176, adjacent to the rearward wall 230, is narrower than the other regions (see e.g., FIGS. 77B and 79B). In some embodiments, the bottom flange 176 has a narrow portion between two wider portions (see e.g., FIG. 93B). The bottom flange 176 includes one or more apertures or slots 165 that are aligned with the mounting features 135/137 of the foot support member 124 to receive a fastener 142 for removably coupling the toe stop 140 to the running board assembly 120 (see e.g., FIGS. 31 and 71). Slots 165 may be U-shaped. The location of one or more of the slots 165 may differ between embodiments of the toe stop 140 (e.g., compare the positions of the inboard, rearward slot 165a in FIG. 79B and 93B) to account for the different positions of the foot support member 124 in the different running board assemblies 120A, 120B. In one non-limiting example, the slot has a diameter of 5 mm to receive a fastener with a 10 mm diameter head. The bottom flange 176 may extend from the rearward wall 230, the inboard wall 171/173, and/or the forward wall 163 (see e.g., FIG. 72). In at least one embodiment, an opening 177 is defined by the bottom flange 176, and the flange portion 129 of the foot support member 124. The opening 177 is positioned below the toe pocket 222 defined by the toe stop 140. Although the opening 177 is shown as being defined by the toe stop 140 and the foot support member 124, it is to be understood that the opening 177 may be entirely defined by the toe stop 140, or the opening may be entirely defined by the foot support member 124.

For example, as shown in FIGS. 71-73, the toe stop 140 may be positioned with the bottom flange 176 positioned over the flange at the forward end of the foot support member 124 with the slots 165a/b of the toe stop 140 aligned with the openings or mounting features 135/137 defined by the foot support member 124 flange to receive the fasteners 142 to removably secure the toe stop 140 thereto. As shown in FIGS. 86B and 87B, one of the openings 135 in the foot support member 124 flange (covered by the bottom-out protector) may be positioned forward of the track drive shaft axis of rotation 350, and opening 137 may be positioned rearward of the track drive shaft axis of rotation 350. For example, the outboard portion of the foot support member 124 may extend forward of the track drive shaft axis of rotation 350, and the inboard side of the foot support member 124 may be positioned rearward of the track drive shaft axis of rotation 350. Similarly, one of the slots 165b on the toe stop 140 (corresponding to the opening 135) may be positioned forward of the track drive shaft axis of rotation 350 and the slot 165a (corresponding to the opening 137) may be positioned rearward of the track drive shaft axis of rotation 350, and both may be positioned outboard of the inboard wall 171. Accordingly spacing is provided for the inboard wall 171 of the toe stop 140 to define a chamber for housing one or more vehicle components while still providing sufficient spacing for the opening 177 to be defined by the toe stop 140 and the foot support member 124 to allow snow to pass therethrough. In another non-limiting example as shown in FIG. 101, the mounting features 135/137 of the foot support member 124 and the openings 165a/165b of the toe stop 140 may all be positioned rearward of the track drive shaft axis of rotation 350. As described in detail below, the bottom-out protector 148 may be removably secured to the underside of the foot support member 124 flange and removably secured thereto to define the opening 177 on the underside of the foot support member 124 (see e.g., FIGS. 31, 57, 86B, and 101) that is aligned with the opening 177 partially defined by the toe stop 140.

In an illustrative example, the slots 165a, 165b of the toe stop 140 (for use with the running board assembly 120A) may be positioned further outboard from the inboard wall 173 and/or other features on the toe stop 140. In addition to, or alternatively, the slots 165a, 165b (and the flange 176) of the pair of toe stops 140c, 140d (for use with running board assembly 120A) may be positioned further outboard from the inboard wall 173 and/or other features on the toe stop 140 than the slots 165a, 165b of the pair of toe stops 140a, 140b (for use with the running board assembly 120B). Changing the location of such features between the pairs of the toe stops 140 allows for the toe stops 140 to be compatible with common components, such as the forward frame 312, between the snowmobile of FIG. 1 and the snowmobile of FIG. 8, as well as with components that are not common or commonly configured (such as the running board assemblies 120A and 120B) between the snowmobile of FIG. 1 and the snowmobile of FIG. 8.

In an illustrative example as shown in FIGS. 74, 77B, 78B and 91A, the outboard wall 197 is positioned at least partially forward of the bottom flange 176 of the toe stop 140. The outboard wall 197 may have a shape that is configured to extend along the toe pocket 222 and include a side panel interface 154 that may be at least partially overlapped by the body paneling 400 and optionally the skid plate 402. The outboard wall 197 may be configured in a V-shape (see e.g., FIGS. 78A-7B). For example, the apex of the V may be oriented towards the outboard side of the snowmobile 100 (see e.g., lines 36 and 37 of FIG. 96A). The side panel interface 154 includes a first portion 198 and a second portion 199 extending forward from the first portion 198 and forward of the toe pocket 222 defined by the toe stop 140 (see e.g., FIG. 27A). One or more ribs 152 extend out from the second portion 199 that is overlapped by one or both of the body paneling 400 and the skid plate 402. The ribs 152 may extend outboard for different lengths (see e.g., FIG. 83B).

Optionally, the outboard wall 197 may include a feature for removably securing the body panel 400 and/or the skid plate 402 thereto. In an illustrative example, the feature may be a mounting point 155 or aperture that is positioned below the bottom rib 152 along the outboard wall 197. The mounting point 155 may be configured to receive a U-clip (see e.g., FIG. 89) that is co-axially aligned with an aperture defined in the mounting point 155. A fastener 321 may be utilized to removably couple the toe stop 140 and the body panel 400 and/or the skid plate 402 together. A skid plate interface 156 extends forward from the first portion 198 and may be positioned below the mounting point 155 (see e.g., FIGS. 26, 27A, and 30). In some implementations, an interior/inboard face of the skid plate 402 overlaps and/or directly contacts the skid plate interface 156 (see e.g., FIG. 85A).

When the toe stop 140 is coupled to the snowmobile 100, the first portion 198 is visible 198 while the second portion 199 including the interfaces 154/156 is positioned behind the body panel 400 and/or the skid plate 402 and is not visible, or only partially visible, when viewed from the side (see e.g., FIGS. 85A-B and 98A-B). The first portion 198 is positioned along the length of the vehicle between the body panel 400 and the support member 122. In some implementations, the one or more ribs 152 abut the inboard (inner) surface of the body panel 400—in other words, the body panel 400 rests on the one or more ribs 152. In one aspect, the space between adjacent ribs 152 and the body panel 400 provide a passageway for air to vent, e.g., underhood hot air may vent (see e.g., FIG. 76). In a non-limiting example, the ribs 152 provide a standoff between the toe stop 140 and the body paneling 400 to define a gap therebetween that is a ventilation feature positioned outboard of the toe pocket 222 for air to flow out of the engine compartment and/or the belt case assembly 354 covered by the body paneling 400 and/or the toe stop 140. As the first portion 198 extends rearward and outboard of the second portion 199, the air flowing out of the gap defined by the toe stop 140 and the body panel 140 deflects off the first portion 198 and flows outboard away from the rider's envelope

The forward wall 163 at least partially defines the toe pocket 222 and separates the toe pocket 222 from the engine compartment. The forward wall 163 may include a lower wall that extends forward and upward from the bottom flange 176, and an upper wall that extends forward and downward from an upper panel 240 of the toe stop 140 (that is positioned forward of the toe grip 141) at least partially forward of the support member 122 and the mounting point 317 of the forward frame 312 to intersect the lower wall. The forward wall 163 may form a V-shape with the apex positioned forward (just below the openings 144) and the open end facing rearward (see e.g., FIG. 77B). The forward wall 163 may form the rearward side of the outboard wall 197 (see e.g., FIG. 74). As shown in FIGS. 74, and 78A-78B, the forward wall 163 may extend inboard from the outboard wall 197 to the inboard wall 171. As discussed above, the forward wall 163 may include one or more openings 144. The openings 144 may extend horizontally from the outboard wall 197 to the inboard wall 171, may optionally only be provided in the upper wall of the forward wall 163. Placement of the openings 144 at the upper portion of the toe pocket 222 allows warm air to flow downward from the engine compartment or belt casing 354 and across the toe pocket 222 while inhibiting snow from entering the engine compartment.

In some implementations, the toe stop 140 is an abutment for one or more components of the running board assembly 120. For example, a portion of the forward wall 163 and/or the outboard wall 197 may form a channel 161 with a rearward facing support face 167 for the support member 122 (see e.g., FIG. 73). In other words, the support member 122 is positioned adjacent to the rearward side of the forward wall 163 and/or outboard wall 197 along the support face 167. As illustrated for example, in FIGS. 85A-85B, when the toe stop 140 is coupled to the snowmobile 100, the support member 122 extends along the forward end of the foot support member 124 where it is received by the toe stop 140 along the lower and upper portions of the rearward facing side of the toe stop 140 (along support face 167). The support member 122 is positioned in the vertical channel 161 as the support tube 122 extends upward and rearward from its forwardmost point of the forward wall 163 before extending inboard through the clearance feature 160 to where it is inserted in the end of the rearward leg 326 or 338 and removably secured thereto with the fastener 125 at the mounting point 317 of the forward frame 312. In some embodiments, the rearward leg 326, 338 may be referred to as a tube extending downward and rearward from the steering column mount. The support member 122 may be exposed on the outboard side 127—in other words it is not covered by a body panel 400, or toe stop 140. The support member 122 may form a continuous tube with the rearward leg 326, 338, the continuous tube may extend from the steering column mount to the rear suspension component 192. In some embodiments, the support member 122 (also referred to as a “member” or “tube”) may be secured to the rear suspension component 192. The rear suspension component 192 may be a component of a rear suspension 111 of the snow vehicle, the rear suspension component 192 connected with a skid rail 115. In some embodiments, the rear suspension 111 may include a rear arm 117 pivotally secured to the skid rail 115. The support member 122 may include a forward portion 360, including a base 362 positioned outboard from a lower edge of the side panel of the tunnel 104, a vertical leg 364 extending upward from the base 362, and a horizontal leg 366 extending inboard from the vertical leg 364. The horizontal leg 366 may defines a first end that is secured to the forward frame 312 at the mounting point 317. The support member 122 may include a rearward portion 370 including a rear base 372 and a leg 374. The rear base 372 may be positioned outboard from a lower edge of a side panel of the tunnel 104, and the leg 374 may include an end that extends inboard from the rear base 372 and is operably secured to the rear suspension component 192.

The toe stop 140 may include one or more features such as a toe hook 141 (see e.g., FIG. 74) positioned in and/or above the toe pocket 222 that provides a grip for the rider's foot. In one aspect, since the toe hook 141 is a part of the unitary toe stop 140, the toe hook 141 is not directly fastened to the frame. In another aspect, since the toe stop 140 is polymeric composite material, the toe stop 140 is not a metal tube, stamped or formed part like a conventional toe stop. In at least one embodiment, the toe hook 141 includes a curved bottom (see e.g., FIG. 81A). In some implementations, the toe hook 141 when viewed from an inboard side includes a recess and a triangular shaped rear wall extending upward from the recess (see e.g., FIG. 80B). The recess of the toe hook 141 as shown in FIG. 90B may have a rectangular or U shape that produces a rectangular or U shape for the took hook 141 as shown in FIG. 90A.

In at least one embodiment, the toe hook 141 is adjacent to a panel 168 that extends inboard therefrom. In some implementations, the toe hook 141 includes an angled edge 234 that extends from the outboard end of the upper edge of panel 168 downward and inward towards the inboard wall 171 (see e.g., FIG. 78A). In one example, the rearward side of the toe hook 141 is an extension of the panel 168 (see also FIG. 78B). In other implementations, the toe hook 141 is positioned under the panel 168 (see e.g., FIGS. 90A and 92A) and the panel 168 extends upward and rearward therefrom. The toe hook 141 may be at least partially positioned rearward of the forward wall 163. The forward wall 163 may extend further outboard than the toe hook 141 (see e.g., FIGS. 78A, 83A, and 92A) to accommodate the forward end of the support member 122. In some implementations, an upper panel 240 is positioned between the forward wall 163 and the toe hook 141 (see e.g., FIG. 91A).

One or more of the outboard wall 197, the inboard wall 171/173, the forward wall 163, the upper panel 240, and the toe hook 141 may define a toe pocket 222 configured to receive at least the toe portion of the rider's foot. In some implementations, the bottom flange 176 and forward wall 163 is substantially C-shaped, with an upper portion of the forward wall 163 curving rearward to form a ceiling of the toe pocket 222 (see e.g., FIG. 31). In other implementations, the upper panel 240 extends rearward from the forward wall 163 to the toe hook 141 to at least partially form the ceiling of the toe pocket 222 (see e.g., FIGS. 74 and 77A). As shown in FIGS. 91A and 94A, at least a portion of the toe hook 141 extends downward into the toe pocket 222 below the upper panel 240.

Optionally, a clearance feature 160 may be positioned forward of and/or above the toe hook 141 (see e.g., FIG. 74) and rearward of the first portion 198. The clearance feature 160 is sized to receive the support member 122 forward of the toe hook 141 (see e.g., FIG. 27A) so that the support member 122 extends inboard forward of the panel 168. In one example, the clearance feature 160 is a U-shaped slot. In some implementations, the U-shaped clearance feature 160 is formed by the panel 168, panel 240, and the outboard wall 197 (see e.g., FIGS. 74 and 91A). The support member 122 may extend alongside and/or rest against the forward facing surface 166 of the panel 168 (see e.g., FIGS. 75 and 88A).

The inboard wall 171/173 extends rearward from the forward wall 163. In one aspect, an inboard surface of the inboard wall 171/173 defines at least a portion of a chamber for receiving a vehicle component therein and thereby separates the rider's foot therefrom. In a non-limiting example, the inboard wall 171 defines a chamber 228 that receives one or more of a belt case assembly including, but not limited to, a belt, a bottom drive sprocket or gear, a belt housing assembly 354, and a track drive shaft 352. Accordingly, the toe stop 140 can eliminate the need for a separate housing components. For example, the belt case does not require a separate cover, which reduces the weight of the belt housing assembly 354 (see e.g., FIG. 28). A portion of the inboard wall 171 may be positioned under the toe hook 141 that extends outboard from the inboard wall.

In an illustrative example, inboard wall 173 may define a chamber 228 that receives a brake component including, but not limited to, a track drive shaft, a rotor 351 and/or a caliper 353 (see e.g., FIG. 88A). As shown in FIGS. 81A, 81B, 94A and 94B, the inboard wall 173 may define a second chamber 229 that extends outboard to receive a portion of the brake assembly or drive shaft therein. In one illustrative example, the second chamber 229 receives an end of the drive shaft 352. The shape of the inboard wall 171/173 and one or more other dimensions of the toe stop 140 such as the width from inboard side to outboard side of the toe stop 140 may differ depending on the drive shaft position of the snowmobile 100 and/or the orientation of the foot support 124. For example, the toe stops 140 shown in FIGS. 77 and 81 may be part of the running board assembly 120A of FIG. 7 wherein the track drive shaft is positioned as shown in FIGS. 42A and 42B. The toe stops 140 shown in FIGS. 90 and 94 may be part of the running board assembly 120B of FIG. 10 wherein the track drive shaft is positioned as shown in FIGS. 42C and 42D. The inboard wall 171/173 may include one or more openings for venting. For example, the inboard wall 171 may include one or more openings 162 (see e.g., FIG. 90B). As another example, the inboard wall 173 may include one or more openings 175 for venting the brake caliper (see e.g., FIG. 81A). As shown in FIG. 85B, the brake caliper 353 may extend through the opening 175 and outboard of at least a portion of the inboard wall 173.

The inboard wall 171/173 may curve inboard to form the rearward wall 230 (see e.g., FIGS. 73, 77A and 96A) that with the inboard wall 171/173 may define the chamber 228/229 for receiving the vehicle component therein (see e.g., FIGS. 78B, 81B, 83B, 87B). The inboard side of the rearward wall 230 may be positioned adjacent the side panel 182 of the tunnel 104 and/or the heat exchanger end cap 178 to form the chamber 228/229 with the inboard wall 171/173 and the side panel 182 and/or heat exchanger end cap 178. The heat exchanger end cap 178 may include those described in U.S. Provisional Patent Application Ser. No. 63/405,176 filed on Sep. 9, 2022, and entitled “RECREATIONAL VEHICLE HEAT EXCHANGER END CAPS AND ASSEMBLY,” the contents of which are incorporated by reference in its entirety. The rearward wall 230 may be shaped to conform with the shape of the component that is housed in the chamber 228/229. In an illustrative example, the rearward wall 230 is shaped to conform with the lower portion of the belt assembly 354 as shown in FIG. 29. In some embodiments, the belt assembly 354 may include a chain assembly and may be received by the toe stop 140 and the bottom out protector 148. The belt assembly 354 may include a separate cover from the toe stop 140 and the bottom out protector 148. In another illustrative example, the rearward wall 230 is shaped to conform to the shape of a brake rotor 351 as shown in FIGS. 87B and 88A. The rearward wall 230 may include one or more openings 231 (see e.g., FIG. 96A) for providing ventilation to the component housed in the chamber 228/229.

The panel 168 may extend inboard from the toe hook 141 and be positioned above the inboard wall 171/173. In some implementations, the rearward surface of the lower portion of the panel 168 abuts or otherwise intersects the rearward surface of the toe hook 141 (see e.g., FIGS. 66 and 74). The panel 168 may extend outboard from the inboard side of the toe stop 140 at an angle that is different than the angle that the toe hook 141 extends outboard from the inboard side 171/173. Accordingly, the inboard side of the panel 168 may be positioned rearward of the outboard end of the panel 168 (see e.g., FIG. 66). The inboard side of the panel 168 may be positioned rearward of the toe hook 141, and the outboard side of the panel 168 may intersect the toe hook 141. The panel 168 may include one or more openings 169. Openings 169 may vent air from the engine bay 108. In one example, the panel 168 has three openings 169 (see e.g., FIG. 75). In another example, the panel 168 has four openings 169 (see e.g., FIGS. 26 and 77). Optionally, one or more ribs 170 may extend over the openings 169 (see e.g., FIG. 26). The ribs 170 may be positioned on the forward side of the panel 168. In one aspect, the ribs 170 add strength to the panel 168.

The panel 168 may include an attachment feature 158 to couple the toe stop 140 to the body panel 400 (see e.g., FIGS. 85A-85B). For example, the upper edge of the panel 168 may include the attachment feature. In some implementations the attachment feature 158 is a hook feature—e.g., the panel 168 includes a hook feature configured to mate with a hook feature of the body panel 400. In other implementations, the panel 168 includes a ledge surface configured for the bottom edge of the body panel 400 to rest upon. The attachment feature 158 may extend along the upper edge of the panel 168 from the outboard side to the inboard side and is positioned forward of a frame mount member 150 extending therefrom.

The frame mount member 150 provides an aperture 151 or another feature for removably securing the toe stop 140 to the forward frame 312. The frame mount member 150 may extend upward from the upper portion of the panel 168. In one example, the frame mount member 150 extends upward and forward from the panel 168 (see e.g., FIG. 27A). In some implementations, the frame mount member 150 extends along only a portion of the upper end of the panel (see e.g., FIG. 66). In other implementations, the frame mount member 150 extends along a majority of the upper end of the panel 168 (see e.g., FIG. 71). In one example, the frame mount member 150 is positioned in the middle of the panel 168 (see e.g., FIG. 90). Optionally, the frame mount member 150 further includes one or more apertures 164 (see e.g., FIG. 71).

The frame mount member 150 may include one or more mounting apertures 151. In one aspect, the toe stop 140 may be coupled to a mounting member 327 of the forward frame 312 by the frame mount member 150. The mounting member 327 is coupled to the rearward leg 326/338 and includes one or more apertures 325 (see e.g., FIGS. 31 and 71). In an illustrative example, the mounting member 327 has a lower aperture 325a, a middle aperture 325b, and an upper aperture 325c that may be utilized for the attachment of different snowmobile components, including the toe stop 140. The frame mount member 150 may be positioned on the mounting member 327 and a fastener 172 may extend through an aperture 151 in the frame mount member 150 and through an aperture 325 in the mounting member 327 (see e.g., FIG. 66). In an illustrative example, the toe stop 140 may be attached via the lower aperture 325a of the mounting member 327 and a guard member 355 may be attached via the middle aperture 325b of the mounting member 327 (see e.g., FIGS. 59, 66, and 88A). The frame mount member 150 may be coupled to the rearward side of the mounting member 327 (see also, FIGS. 27A, and 28). When the toe stop 140 is coupled to a snowmobile 100, the frame mount member 150 is positioned inside the chamber formed by the body panel 400 (see e.g., FIGS. 85A-85B and 98A-98B) and the panel 168, so that it is not visible on the exterior of the snowmobile with the body panel 400 installed.

The toe stop 140 may include one or more sensor mount/mounting features 143 for a sensor 145 (see, FIGS. 26, 27A, 79A-79B). The sensor mount 143 may be located or otherwise accessible from the inboard surface of the inboard wall 171/173. In an illustrative example, the inboard wall 171 may include a sensor mount 143 (se e.g., FIGS. 77A, 80A, 80B, 90A, 90B, and 91B). As shown in FIG. 26, the sensor 145 may include a wire/cable 183 and a connector 196 (see e.g., FIG. 29). In some embodiments, the sensor 145 is a speed sensor that detects movement of the track drive shaft or a component operably connected thereto. At least a portion of the sensor 145 may be fabricated from a polymeric material. As illustrated in FIG. 26, the mount 143 may define a channel on the inboard side of the inboard wall 171/173 with an open end at the top, and the sensor 145 may slide into the channel of the sensor mount 143 through the opening at the top until the bottom of the sensor 145 is supported by the bottom/closed end of the channel of the sensor mount 143. As shown in FIG. 86A, the sensor 145 is secured in the sensor mount 143 opposite the track drive shaft 352 or a component of the belt housing assembly 354 to sense rotation or movement thereof for one or more purposes, including, but not limited to, measuring or calculating the speed of the vehicle. A gap is provided between the sensor 145 and the object being measured by the offset provided between the tunnel 104 (or heat exchanger end cap 178) and the inboard wall 171/173 by the rearward wall 230. In one aspect, the sensor mount 143 is configured to provide a snug fit with the sensor 145 without mechanical fasteners—in other words by an interference fit. The sensor cable 183 may extend from the sensor mount 143 so that at least a portion of it is positioned inboard from the toe stop 140 and forward from the panel 168 and frame mount member 150 (see also FIGS. 29 and 31). The sensor cable 183 may be forward of the rearward leg 326. The sensor cable 183 may be further positioned rearward of the belt housing assembly 354. In one aspect, the arrangement positions the sensor 145 outside the belt housing assembly 354. In one aspect, the mount 143 extends from the inboard surface of the inboard wall 171/173 to position the sensor 145 at least partially within the belt housing assembly 354 but spaced apart from any component in the belt housing assembly 354 and supported only by the toe stop mount 140.

The position of the mount 143 and the sensor 145 on the inboard wall 171/173 may depend on the location of the track drive shaft 352 and/or the belt housing assembly 354. As shown from the inboard view of FIG. 80A (and from the outboard view of FIG. 77B), the location of at least a portion of the toe hook 141 along the vehicle may overlap with a portion of the mount 143, and optionally the toe hook 141 overlaps with the track drive shaft 352 or the axis of rotation of the track drive shaft 352 along the length of the vehicle when the track drive shaft 352 and belt housing assembly 354 are provided in the position shown in FIGS. 42A and 42B. As shown from the inboard view of FIG. 90B (and from the outboard view of FIG. 90A), the location of at least a portion of the toe hook 141 along the vehicle may positioned rearward of the mount 143, and optionally the toe hook 141 is positioned rearward of the track drive shaft 352 or the axis of rotation of the track drive shaft 352 along the length of the vehicle when the track drive shaft 352 and belt housing assembly 354 are provided in the position shown in FIGS. 42C and 42D. Accordingly, the position of the toe hook 141 with respect to the forward frame assembly 312 is maintained in the same location for the first snowmobile of FIG. 1 and the second snowmobile of FIG. 8, even though different toe stops 140 are used. In both illustrative examples, the toe grip or hook 141 may be provided forward of the rearwardmost position of the belt or the belt housing assembly 354. In addition to, or alternatively, the toe hook 141 may at least partially overlap the track drive shaft axis of rotation as evidenced by the chamber (or projection) 229 as shown in FIG. 82A that receives the track drive shaft 352 therein or be positioned entirely almost rearward of it as shown in FIG. 94A depending on the location of the track drive shaft 352.

The toe stop 140 may include a wire retaining feature 159, as shown in FIG. 80B, for one or more vehicle components. In some implementations, the wire retaining feature 159 forms a part of or is otherwise defined by a portion of the toe hook 141 (see also, FIG. 27A). The wire retaining feature 159 may comprise one or more fingers extending inboard from an inboard surface of the toe hook 141 to retain the wire therebetween inside of the body panel 400. In other implementations, the wire retaining feature 159 forms a part of or is otherwise defined by a portion of the panel 240 positioned forward of the toe hook 141 and rearward of the outboard wall 197 (see e.g., FIG. 90A). In such an illustrative example, the wire retaining feature 159 may include on or more fingers extending inboard from an inboard surface of the panel 240 to retain the wire therebetween inside of the body panel 400, and may be positioned along or beneath the clearance feature 160.

In some implementations, the wire retaining feature 159 is configured to hold and/or secure the position of one or more wires/cables 183 of the sensor 145 in the sensor mount 143. In one non-limiting example, the wire retaining feature 159 includes two keys or fingers to route the wire/cable 183 and retain it at that position. In one implementation, the wire retaining feature 159 includes an aperture on an outboard side of the toe stop 140 so that a tool can access the wire retaining feature 159 positioned on the inboard side of the toe stop 140 and secure the sensor wire/cable 183 to the wire retaining feature 159. As discussed above, the belt case drive assembly 354 may not include a cover so, in one aspect, the wire retaining feature 159 positions the sensor wire/cable 183 away from the drive train 112.

In an illustrative example, the toe stop 140 includes a wire guide 157. The channel 157 may be included in a wall 232 that extends rearward from the inboard wall 171/173 and/or the rearward wall 230. The channel 157 is partially defined by the side panel 182 of the tunnel 104 or the heat exchanger end cap 178 when the wall 232 is positioned thereagainst. The channel 157 includes an open end at a forward end of the wall 232 so that a wire or other item can be routed from inside the region enclosed by the toe stop 140 and the body panel 400 through the open end and rearward along the side panel 182 or the end cap 178. An aperture is provided in the side panel 182 or the end cap 178 for routing the wiring to, for example, a suspension component. In some implementations, the wire guide 157 guides, locates, protects, and/or secures a wire extending from the main harness to the rear suspension. The wire guide 157 may be a channel in a panel/wall 232 extending from the rearward wall 230 (see e.g., FIGS. 74 and 75).

In at least one embodiment, method 200 further includes attaching a toe stop to the foot support member. In a non-limiting example, the method includes attaching a first pair of toe stops 140 (as shown in FIGS. 77A and 81A) to a common forward frame assembly 312 for use with the snowmobile of FIG. 1, and attaching a second pair of toe stops 140 (as shown in FIGS. 90A and 94A) to a common forward frame assembly 312 for use with the second snowmobile of FIG. 8. The first pair of toe stops 140 and the second pair of toe stops 140 may include one or more features commonly positioned with respect to the forward frame assembly 312 (in the same location for both pairs) including, but not limited to, the frame mount member 150, the toe hook 141, the side panel interface 154, the mounting point 155, the skid plate interface 156, and the attachment feature 158. In a non-limiting example, one or more features may be positioned differently with respect to the forward frame assembly 312 (in different locations for the pairs) including, but not limited to, the chambers 228, 229, the sensor mount 143, and slots 165a and 165b. In a non-limiting example, the width of the rearward facing support face 167 may be different between the two pairs.

In at least one embodiment, method 200 further includes attaching a toe stop to the foot support member.

In at least one embodiment, method 200 further includes attaching a toe stop to the foot support member.

According to one or more aspects of the present disclosure, a toe stop includes a composite body that includes: a first portion defining a toe pocket; and a second portion at least partially defining a chamber positioned inboard of the toe pocket, wherein the chamber is shaped to at least partially house a vehicle component therein.

In one or more embodiments of the toe stop according to the previous paragraph, the chamber is partially defined by an inboard wall, the inboard wall comprising a sensor mount configured to receive a sensor.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the chamber is partially defined by a rearward wall extending inward from the inboard wall, the composite body further comprising a wire guide panel extending from the rearward wall, the wire guide panel comprising a wire guide.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe pocket is partially defined by a toe hook and a forward wall and the toe hook is positioned rearward of the forward wall.

According to one or more aspects of the present disclosure, a toe stop includes a composite body. The composite body includes a first portion defining a toe pocket; and a wall positioned inboard of the first portion and extending rearward therefrom, wherein an inboard side of the wall defines a channel configured to receive at least a portion of a wire harness for an electrical component therein.

According to one or more aspects of the present disclosure, a toe stop includes a composite body. The composite body includes a toe pocket; and a wall positioned inboard of the toe pocket and extending rearward therefrom, wherein the wall defines a sensor mount.

In one or more embodiments of the toe stop according to the previous paragraph, the toe hook is further positioned above the sensor mount.

According to one or more aspects of the present disclosure, a toe stop includes a unitary body. The unitary body includes a bottom flange forming a bottom surface of the top stop; a forward wall extending upward from the bottom flange; an inboard wall extending upward from the bottom flange and rearward from the forward wall; and a rearward wall extending upward from the bottom flange and inward from the inboard wall. A toe pocket is partially defined by the forward wall and the inboard wall.

In one or more embodiments of the toe stop according to the previous paragraph, the bottom flange includes one or more slots for attaching the toe stop to a running board assembly of a snowmobile.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the unitary body further including an outboard wall positioned forward of the bottom flange and extending forward from the forward wall. The outboard wall includes a side panel interface and/or a skid plate interface.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the outboard wall includes the side panel interface and the skid plate interface, wherein the side panel interface is positioned above the skid plate interface.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the outboard wall is V-shaped.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop further including one or more ribs extending outward from an outboard surface of the outboard wall.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the outboard wall includes a skid plate mounting point located above the skid plate interface.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the skid plate mounting point is further located below the one or more ribs.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the unitary body further includes a toe hook positioned rearward of the forward wall, wherein the toe pocket is further defined by the toe hook.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe hook comprises a wire retaining feature positioned on an outboard side of the toe hook.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe hook has a triangular or rectangular shape.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop further includes a toe hook panel positioned forward of the forward wall, above the inboard wall, and rearward of the rearward wall, the toe hook extending inboard to an inboard side of the toe stop; and a frame mount member extending upwards from an upper edge of the toe hook panel, the frame mount member including a mounting aperture for mounting the toe stop to a forward frame.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe hook is positioned along a rearward surface of the toe hook panel.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe hook is positioned along a bottom surface of the toe hook panel.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe hook panel defines one or more openings.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop including one or more ribs extend over the one or more openings.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the ribs are positioned on a forward surface of the toe hook panel.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, an upper edge of the toe hook panel includes an attachment feature for coupling the toe stop to a body panel of a snowmobile.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop further includes a panel extending forward from the toe hook to the forward wall. The panel, the toe hook and the forward wall define a clearance feature sized to receive a tubular running board support member.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the inward wall and the rearward wall defining a chamber for a belt assembly positioned inboard from the toe stop.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the inward wall and the rearward wall defining a chamber for a belt assembly positioned inboard from the toe stop.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop including one or more vent holes.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the one or more vent holes includes a vent hole in the inboard wall, the forward wall, and/or the rearward wall.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, a forward surface of the toe stop includes one or more ribs.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop is unitary.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop is a molded polymeric composite material.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop further including a sensor coupled to the sensor mount feature by an interference fit.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stop is coupled to a running board assembly of a snowmobile.

According to one or more aspects of the present disclosure, a snowmobile, includes a body including a tunnel and a running board assembly secured to the body. The running board assembly including a support member positioned outboard of the tunnel, and a foot support member having an inboard side removably secured to the tunnel. A toe stop is coupled to the foot support member, wherein the toe stop is a molded polymeric composite material.

In one or more embodiments of the toe stop according to the previous paragraph, the foot support member is formed of a material having thermal conductivity of less than 1 W/m-° K.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the support member and the foot support member are removably attached to the tunnel and the foot support member is removably secured to the support member.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the foot support member defines a plurality of apertures extending from near the inboard side to near the outboard side of the foot support member and configured to shed snow or other debris therethrough.

In one or more embodiments of the toe stop according to any one of the previous paragraphs, the toe stops define a plurality of openings in fluid communication with an engine bay of the snowmobile. The openings are configured to exhaust air warmed by the engine from inside the engine bay.

According to one or more aspects of the present disclosure, a method of assembling a snowmobile that includes a body defining a tunnel is presented. The method includes attaching a support member to the tunnel using a first plurality of fasteners such that the support member is located outboard of the tunnel; attaching inboard sides of a foot support member to the tunnel using a second plurality of fasteners; securing outboard sides of the foot support member to the support member using a plurality of flexible clips integrally formed with the foot support member that is defined on an outboard side of the foot support member; and attaching a toe stop to the foot support member using one or more second fasteners, the toe stop comprising a bottom flange with one or more slots, each slot configured to receive one of the second fasteners.

In one or more embodiments of the method according to the previous paragraph, the toe stop comprises a plurality of openings and attaching the toe stop includes arranging the plurality of openings such that they are in fluid communication with an engine bay of the snowmobile and configured to exhaust air warmed by the engine from inside the engine bay.

According to one or more aspects of the present disclosure, a snowmobile includes a body including a tunnel and a running board assembly secured to the body. The running board assembly further includes a support member positioned outboard of the tunnel, a foot support member having an inboard side removably secured to the tunnel, and an outboard side removably secured to the support member by a plurality of flexible clips defined on an outboard side of the foot support member. Each of the flexible clips wraps around at least 51% of a circumference of the support member and is sized to apply a compressive force to the support member.

In one or more embodiments of the snowmobile according to the previous paragraph, each of the flexible clips wraps around at least 60% of a circumference of the support member.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, each of the flexible clips wraps around no more than 75% of a circumference of the support member.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the foot support member is formed of a material having thermal conductivity of less than 1 W/m-° K.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the foot support member is formed of a polymeric composite material.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the plurality of flexible clips are integrally formed with the foot support member of the same polymeric composite material.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the support member and the foot support member are removably attached to the tunnel and the foot support member is removably secured to the support member.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the support member is removably attached to the tunnel by a plurality of threaded fasteners.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the foot support member defines a plurality of apertures extending from near the inboard side to near the outboard side of the foot support member and configured to shed snow or other debris therethrough.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the foot support member defines a plurality of serrated ridges extending from a top surface of the foot support member and located intermediate the plurality of apertures. The plurality of serrated ridges are configured to enhance traction of a rider's boot with the running boards.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the running board assembly further includes front toe stops attached to the foot support member and the tunnel.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the front toe stops define a plurality of openings in fluid communication with an engine bay of the snowmobile. The openings are configured to exhaust air warmed by the engine from inside the engine bay.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the running board assembly further includes rear kick-up panels that are attached to the foot support member and the tunnel.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the snowmobile further includes bottom-out protectors that project from the body and are located outboard of the tunnel and are located inboard of the support member of the running board assembly. The bottom-out protectors are positioned on the body in a location lower than the tunnel and the foot support member.

In one or more embodiments of the snowmobile according to any one of the previous paragraphs, the bottom-out protectors are formed from an unfilled thermoplastic olefin material.

According to one or more aspects of the present disclosure, a method of assembling a snowmobile that includes a body defining a tunnel is presented. The method includes attaching a support member to the tunnel using a first plurality of fasteners such that the support member is located outboard of the tunnel, attaching inboard sides of a foot support member to the tunnel using a second plurality of fasteners and securing outboard sides of the foot support member to the support member using a plurality of flexible clips integrally formed with the foot support member that is defined on an outboard side of the foot support member. Each of the flexible clips wraps around at least 51% and at most 75% of a circumference of the support member and is sized to apply a compressive force to the support member.

In one or more embodiments of the method according to the previous paragraph, the method further includes attaching front toe stops to the foot support member and the tunnel and arranging a plurality of openings in the front toe stops such that they are in fluid communication with an engine bay of the snowmobile and configured to exhaust air warmed by the engine from inside the engine bay.

In one or more embodiments of the method according to any one of the previous paragraphs, the method further includes attaching rear kick-up panels to the foot support member and the tunnel.

In one or more embodiments of the method according to any one of the previous paragraphs, the method further attaching bottom-out protectors formed from an unfilled thermoplastic olefin material to the body. The bottom-out protectors are located outboard of the tunnel and inboard of the support member to which the plurality of flexible clips defined on the outboard side of the foot support member are secured. The bottom-out protectors are positioned on the body in a location lower than the tunnel and the foot support member.

According to one or more aspects of the present disclosure, a snowmobile includes a chassis, a tunnel attached to the chassis, a running board assembly, and bottom-out protectors projecting from the chassis and located outboard of the tunnel and inboard of an outboard side of the running board assembly. The bottom-out protectors are positioned on the chassis in a location lower than the tunnel and the running board assembly. The bottom-out protectors are formed from a thermoplastic olefin material.

According to one or more aspects of the present disclosure, a composite running board includes a first side rail that is securable to a snowmobile and a second side rail positioned outboard of the first side rail. The second side rail at least partially defines a channel shaped to receive a support. The composite running board further includes a plurality of cross members extending from the first side rail to the second side rail.

In one or more embodiments of the composite running board according to the previous paragraph, the channel extends along a length of the second rail.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, the support has a tubular shape.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, the lower surface of the running board defines the channel and the lower surface of the running board that defines the channel is curved to form a downward facing opening that extends along a length of the second side rail for receiving a support in the channel.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, a first plurality of retaining members extend toward the opening from the second rail along an outboard side of the downward facing opening.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, the second side rail defines a first plurality of upwardly facing holes on the upper surface to the channel. The first plurality of upwardly facing holes are aligned along the length of the second side rail. At least some of the first plurality of retaining members are positioned outboard and adjacent the first plurality of upwardly facing holes.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, a first plurality of retaining members extend toward the opening from the lower surface of the running board along an inboard side of a downwardly facing opening.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, a second plurality of retaining members extend toward the opening from the lower surface of the running board along an inboard side of the downwardly facing opening.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, the second side rail defines a second plurality of upwardly facing openings on the upper surface to the channel that are aligned along the length of the second side rail. The second plurality of upwardly facing openings are positioned on an inboard side of the channel and the first plurality of openings are positioned on an outboard side of the channel.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, a first plurality of retaining members extend toward the opening from the second rail along an outboard side of the downward facing opening.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, the first plurality of retaining members are offset from the second plurality of retaining members along the length of the second rail.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, the first plurality of upwardly facing openings and the second plurality of upwardly facing openings are offset from each other along the length of the second side rail.

In one or more embodiments of the composite running board according to any one of the previous paragraphs, the first plurality of retaining members are at least partially positioned along a leading edge of the cross members and extend outboard therefrom toward the downwardly facing opening.

According to one or more aspects of the present disclosure, a composite running board includes a first side rail securable to a snowmobile and a second side rail positioned outboard of the first side rail. The second side rail includes a plurality of features that are fastenable to a support member. The composite running board further includes a plurality of cross members extending from the first side rail to the second side rail. The first side rail, the second side rail, and the cross members include a fiber reinforced polymer.

According to one or more aspects of the present disclosure, a composite running board includes a first side rail that is securable to a snowmobile and a second side rail positioned outboard of the first side rail, the second side rail at least partially defines retaining member shaped to engage a support. The composite running board further includes a plurality of cross members extending from the first side rail to the second side rail. The first side rail, the second side rail, and the cross members include a fiber reinforced polymer.

According to one or more aspects of the present disclosure, a composite running board includes a first side rail securable to the side of a snowmobile and a second side rail positioned outboard of the first side rail. The second side rail includes an outboard edge that defines a channel extending along a length of the second rail and shaped to receive a plurality of support members. The composite running board further includes a plurality of cross members extending from the first side rail to the second side rail.

According to one or more aspects of the present disclosure, a snowmobile tunnel assembly includes a tunnel including a center plate and a first side panel including a first end connected to the center plate and a second end extending therefrom. The snowmobile tunnel assembly further has a second side panel including a first end connected to the center plate and a second end extending therefrom. The snowmobile tunnel assembly additionally includes a first running board support secured to the first side panel. The first running board support has a mounting surface extending outboard from the first side panel.

In one or more embodiments of the snowmobile tunnel assembly according to the previous paragraph, the first side panel has a first thickness and the mounting surface of the first support has a second thickness that is greater than the first thickness.

In one or more embodiments of the snowmobile tunnel assembly according to any one of the previous paragraphs, the tunnel includes a first material and the first running board support includes a second material that is different than the first material.

In one or more embodiments of the snowmobile tunnel assembly according to any one of the previous paragraphs, the first support includes a first vertical member that is secured to an inboard surface of the first panel. The mounting surface extends from the vertical member beneath the second end of the first panel and outboard therefrom.

In one or more embodiments of the snowmobile tunnel assembly according to any one of the previous paragraphs, the snowmobile tunnel assembly further includes a running board including a first side rail, a second side rail, and a plurality of cross members extending between the first rail and the second rail. The running board is secured to the mounting surface with the first side rail positioned adjacent and parallel to the first side panel of the tunnel.

In one or more embodiments of the snowmobile tunnel assembly according to any one of the previous paragraphs, the snowmobile tunnel assembly further includes a running board including a first side rail, a second side rail, and a plurality of cross member extending between the first rail and the second rail. The running board is secured to the mounting surface with the first side rail positioned adjacent to the first side panel of the tunnel. A rearward end of the first side rail is positioned a first distance from the first side panel and a forward end of the first side rail is positioned at a second distance from the first side panel that is greater than the first distance.

In one or more embodiments of the snowmobile tunnel assembly according to any one of the previous paragraphs, the mounting surface has a length extending at least partially between a forward end of the tunnel and a rearward end of the tunnel. The mounting surface extends outboard from the first panel a distance at the forward end that is greater than a distance at the rearward end.

In one or more embodiments of the snowmobile tunnel assembly according to any one of the previous paragraphs, the first support includes a rear suspension mounting point vertically offset from the mounting surface.

According to one or more aspects of the present disclosure, a method of making a snowmobile with a common running board is presented. The method includes providing a tunnel assembly including a tunnel including a center plate, a first side panel including a first end connected to the center plate and a second end extending therefrom, and a second side panel including a first end connected to the center plate and a second end extending therefrom and securing either a first running board support or a second running board support to the first side panel. The first running board support includes a mounting surface with a first dimension and the second running board support includes a mounting surface with a second dimension that is different than the first dimension. The method further includes securing a common running board including a longitudinal centerline to the mounting surface of either the first running board support or the second running board support. The longitudinal centerline of the running board is positioned at a first angle with respect to the first side panel when secured to the first running board support and is positioned at a second angle with respect to the first side panel when secured to the second running board support. The first angle is different than the second angle.

In one or more embodiments of the method according to the previous paragraph, the method further includes providing a common forward frame assembly including a first side including a tube mounting member and an inner perimeter defining a first opening, a second side positioned adjacent the first side, the second side including a tube mounting member and an inner perimeter defining a second opening. A rearward portion of the first side and the second side define a rearward opening therebetween. The method additionally includes securing the tunnel assembly to the forward frame with a portion of the tunnel assembly positioned in the rearward opening between the first side and the second side and securing either a first running board support tube associated with the first running board support to the tube mounting member on the first side of the forward frame assembly, or a second running board support tube associated with the second running board support to the tube mounting member on the first side of the forward frame assembly. The first running board support tube has a length that is different than the second running board support tube. The method also includes securing a second side rail of the common running board that is positioned outboard of a first side rail of the common running board to either the first running board support tube or the second running board support tube.

According to one or more aspects of the present disclosure, a method of assembling two different types of snowmobiles with a common forward frame is presented. The method includes providing a common forward frame including a longitudinal centerline and a running board mounting point positioned outboard of the longitudinal centerline, providing a first running board assembly, e.g., a running board assembly of a high performance snowmobile having a shorter chassis, including a forward mount, providing a second running board assembly that is different than the first running board assembly, e.g., a running board assembly of a snowmobile designed for hills and mountains having a longer chassis, the second running board assembly including a forward mount, and securing the forward mount of either the first running board assembly or the second running board assembly to the running board mounting point. The first running board assembly is located at a first position with respect to the longitudinal centerline of the forward frame when secured to the running board mounting point. The second running board assembly is located at a second position with respect to the longitudinal centerline of the forward frame when secured to the running board mounting point. The first position is different than the second position.

In one or more embodiments of the method according to the previous paragraph, the running board mounting point extends outward and forwardly from the forward frame.

In one or more embodiments of the method according to any one of the previous paragraphs, the running board mounting point is positioned below an upper surface of a tunnel secured to the forward frame.

In one or more embodiments of the method according to any one of the previous paragraphs, the forward mount of the first running board assembly extends outward from the centerline of the vehicle farther than the forward mount of the second running board assembly.

In one or more embodiments of the method according to any one of the previous paragraphs, the common forward frame includes a control arm mounting point and the method further includes providing a first suspension assembly including a control arm and a spindle that includes a lower A-arm ball joint, providing a second suspension assembly that is different than the first suspension assembly, the second suspension assembly including a control arm and a spindle that includes a lower A-arm ball joint; and securing the control arm of the first suspension assembly to the control arm mounting point when the first running board assembly is secured to the forward mount or the second suspension assembly to the control arm mounting point when the second running board assembly is secured to the forward mount. The first lower A-arm ball joint is positioned at a different position with respect to the common frame, e.g., from or along the common front frame, than the second lower A-arm ball joint when the respective suspension assembly is secured to the common front frame.

In one or more embodiments of the method according to any one of the previous paragraphs, the forward mount of the first running board assembly extends outward from the centerline of the vehicle farther than the forward mount of the second running board assembly, and the lower A-arm ball joint of the first suspension assembly extends outward from the centerline of the vehicle farther than the lower A-arm ball joint of the second suspension assembly.

In one or more embodiments of the method according to any one of the previous paragraphs, the forward mount of the first running board assembly extends outward from the centerline of the vehicle farther than the forward mount of the second running board assembly, and the lower A-arm ball joint of the first suspension assembly farther forward with respect to the common frame than the lower A-arm ball joint of the second suspension assembly.

In one or more embodiments of the method according to any one of the previous paragraphs, the forward mount of the first running board assembly extends outward from the centerline of the vehicle farther than the forward mount of the second running board assembly, and the lower A-arm ball joint of the first suspension assembly is positioned along the centerline of the forward frame farther forward from the running board mounting point than the lower A-arm ball joint of the second suspension assembly.

While the disclosed snowmobile has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention is not limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. A toe stop, comprising: a body comprising a polymeric material, the body including: a first portion defining a toe pocket; anda second portion positioned inboard of the toe pocket,wherein the second portion at least partially defines a chamber that is shaped to house a vehicle component therein.

2. The toe stop of claim 1, wherein the chamber is partially defined by an inboard wall, the inboard wall comprising a sensor mount configured to receive a sensor.

3. The toe stop of claim 2, wherein the chamber is partially defined by a rearward wall extending inward from the inboard wall, the body further comprising a wire guide panel extending from the rearward wall, the wire guide panel comprising a wire guide.

4. The toe stop of claim 3, wherein the toe pocket is partially defined by a toe hook and a forward wall, wherein the toe hook is positioned rearward of the forward wall.

5. The toe stop of claim 4, wherein the toe hook is positioned above the sensor mount.

6. The toe stop of claim 5, wherein the toe hook includes a wire retaining feature configured to retain a wire inside of the body.

7. The toe stop of claim 4, wherein the forward wall includes one or more openings configured to receive an exhaust air therethrough.

8. The toe stop of claim 7, wherein the forward wall further includes one or more ribs positioned adjacent to the one or more openings.

9. The toe stop of claim 2, wherein the sensor mount is configured to secure the sensor via an interference fit.

10. A toe stop, comprising: a body comprising a polymeric material, the body including: a first portion defining a toe pocket, wherein the first portion includes a base that at least partially defines an opening through a bottom of the toe pocket;a second portion positioned inboard of the toe pocket, wherein the second portion at least partially defines a chamber shaped to house a vehicle component therein; anda toe hook positioned above the opening through the toe pocket.

11. The toe stop of claim 10, wherein the body includes a third portion positioned outboard of the second portion and the toe hook, wherein the third portion includes a rearward facing side shaped to receive a support member of a running board at least partially forward of the toe hook.

12. The toe stop of claim 11, wherein the body includes a first panel interface extending forward from a forward facing side of the third portion, wherein the first panel interface includes an outboard side positionable along an interior surface of a side body panel.

13. The toe stop of claim 12, wherein the body includes a second panel interface positioned inboard of the third portion that extends upward from one or both of the first portion and the second portion, wherein the second panel interface includes an engagement feature that is securable to the side body panel, and wherein the body includes a chassis mount positioned forward of the engagement feature of the second panel interface.

14. The toe stop of claim 13, wherein the chassis mount is positioned rearward of the toe stop.

15. The toe stop of claim 14, wherein the body includes a sensor mount positioned in the chamber.

16. A toe stop comprising: a housing including: a first wall including a first side that is positionable adjacent a tunnel of a tracked snow vehicle, and a second side that extends outboard from the first side;a second wall extending forward of the first wall, wherein a forward-facing side of the first wall and an inboard side of the second wall at least partially define a chamber shaped to receive a vehicle component therein when the first side of the first wall is positioned adjacent the tunnel of the tracked snow vehicle;a toe pocket positioned outboard of the chamber, the toe pocket is at least partially defined by an outboard side of the second wall, an upper wall extending outboard from the second wall, and a first portion of a third wall extending outboard from the second wall;an outboard flange defined by a second portion of the third wall extending outboard of the first portion and the toe pocket, wherein a third portion is positionable between a running board support and a forward body panel of the tracked snow vehicle;a toe hook extending along the upper wall, the toe hook positioned rearward of the third wall and inboard of the outboard flange.

17. The toe stop of claim 16, further comprising a first panel interface including a first end secured to one or more of the first wall, the second wall, and the upper wall, and a second end that extends upward and rearward therefrom, wherein the second end of the first panel interface includes an engagement feature that is securable to the forward body panel.

18. The toe stop of claim 17, further comprising a second panel interface including a first end secured to a forward-facing side of the third wall, and a second end extending forward therefrom, wherein the forward body panel is positioned on an outboard side of the second panel interface when the forward body panel is secured to the engagement feature on the first panel interface.

19. The toe stop of claim 18, further comprising a chassis mount that extends upward and forward from the first panel interface, wherein the chassis mount is positioned forward of the engagement feature of the first panel interface.

20. The toe stop of claim 16, further comprising a running board interface that includes a first portion that extends along a base of the outboard side of the second wall and a second portion that extends along a base of a rearward-facing side of the third wall, wherein the running board interface defines an opening with a running board when the running board is secured to the first portion and the second portion of the running board interface.

21. A snow vehicle, comprising: a track operably positioned in a tunnel, wherein the track is driven by a track drive shaft;a body comprising a polymeric material, the body including: a first portion defining a toe pocket, anda second portion positioned inboard of the toe pocket, wherein the second portion at least partially defines a chamber; anda vehicle component operably connected to the track drive shaft, wherein the vehicle component is at least partially positioned in the chamber defined by the second portion of the body.

22. The snow vehicle of claim 21, further comprising a running board comprising a polymeric material, wherein the running board includes a forward end secured to the body, wherein the forward end of the running board and the body define an opening in the toe pocket.

23. The snow vehicle of claim 22, wherein the body includes a toe hook positioned above the opening in the toe pocket.

24. The snow vehicle of claim 23, wherein the body includes a third portion positioned outboard of the second portion, wherein the running board includes an outboard side that is supported by an outboard member, wherein the body receives a forward portion of the outboard member along the third portion.

25. The snow vehicle of claim 24, wherein the body includes a first panel interface extending forward from the third portion, wherein the first panel interface includes an outboard side, wherein a side body panel is positioned over the outboard side of the first panel interface to position the third portion between the side body panel and the outboard member.

26. The snow vehicle of claim 25, wherein the body includes a second panel interface extending upward from one or both of the first portion and the second portion, wherein the second panel interface includes an engagement feature that is secured to the side body panel, and wherein the body includes a chassis mount secured to a chassis of the snow vehicle, wherein the chassis mount is positioned forward of the engagement feature of the second panel interface and inside of the side body panel.

27. The snow vehicle of claim 21, further comprising a sensor secured to the body and is positioned to detect rotation of the vehicle component.