All-terrain vehicle

An all-terrain vehicle, comprising:

• a frame;
• wheels comprising a left front wheel, a right front wheel and rear wheels;
• a suspension system, comprising a front suspension and a rear suspension;
• the front wheels connected to the frame by the front suspension and the rear wheels connected to the frame by the rear suspension, wherein the front suspension, for each of the left and right front wheels, comprises a respective upper rocker A-arm pivotally connected to the frame, a respective lower rocker A-arm pivotally connected to the frame, and a respective front knuckle connected between the respective upper and lower rocker A-arms and the respective wheel, each upper rocker A-arm having an upper rocker A-arm length, each lower rocker A-arm having a lower rocker A-arm length, wherein a rocker A-arm length ratio of the upper rocker A-arm length to the lower rocker A-arm length is in the range from 0.5 to 1.15;
• a prime mover assembly, at least partially disposed on the frame, for providing locomotive power to rotationally drive the wheels;
• and
• a drive train at least partially disposed on the frame for transmitting torque from the prime mover assembly to the wheels, the drive train comprising a front differential and left and right front half shafts, wherein the half shafts slope downwardly and outwardly, defining a half shaft front view projection angle in front view and relative to horizontal in the range from 0° to 60°;
• wherein each front knuckle comprises a main body defining a front axle bore, an upper connecting portion for connecting to the respective upper rocker A-arm, and a lower connecting portion for connecting to the respective lower rocker A-arm;
• and wherein at least one of the upper connecting portion and the lower connecting portion is separately formed from the main body with a flange connected to the main body by a plurality of bolts inserted into bolt holes, the bolt holes defining a flange centerline, such that a camber adjusting spacer can be positioned between the flange and the main body, with the camber adjusting spacer installed entirely on only one side of the flange centerline, to adjust camber of the respective front wheel.

A method of adjusting camber of at least one front wheel of an all-terrain vehicle, the all-terrain vehicle comprising:

• a frame;
• wheels comprising a left front wheel, a right front wheel and rear wheels;
• a suspension system, comprising a front suspension and a rear suspension;
• the front wheels connected to the frame by the front suspension and the rear wheels connected to the frame by the rear suspension, wherein the front suspension, for each of the left and right front wheels, comprises a respective upper rocker A-arm pivotally connected to the frame, a respective lower rocker A-arm pivotally connected to the frame, and a respective front knuckle connected between the respective upper and lower rocker A-arms and the respective front wheel;
• a prime mover assembly, at least partially disposed on the frame, for providing locomotive power to rotationally drive the wheels;
• and
• a drive train at least partially disposed on the frame for transmitting torque from the prime mover assembly to the wheels;
• wherein each front knuckle comprises a main body defining a front axle bore, an upper connecting portion for connecting to the respective upper rocker A-arm, and a lower connecting portion for connecting to the respective lower rocker A-arm;
• and wherein at least one of the upper connecting portion and the lower connecting portion is separately formed from the main body with a flange connected to the main body by at least one fastener, with a first camber adjusting spacer positioned between the flange and the main body to set camber of the respective front wheel;
• wherein the method comprises:
• loosening the at least one fastener without removing the at least one fastener from the flange and without removing the at least one fastener from the main body, such that the flange can be moved slightly relative to the main body of the front knuckle;
• removing the first camber adjusting spacer from the front knuckle;
• inserting a second camber adjusting spacer into a position previously occupied by the first camber adjusting spacer, between the flange and the main body of the front knuckle, the second camber adjusting spacer being a different thickness than the first camber adjusting spacer;
• and
• tightening the at least one fastener to set camber of the respective front wheel at an adjusted camber.