Description:FIELD OF THE INVENTION
[001] The present invention generally relates to a saddle type vehicle. More particularly, the present invention relates to a front fork assembly of a saddle type vehicle.

BACKGROUND OF THE INVENTION
[002] Generally, in a saddle type vehicle, especially a motorcycle type saddle type vehicle, a pair of front forks connect the wheels, the upper bracket and the lower bracket through the head pipe for transferring steering motion provided on the handlebar to the wheels. One of the primary requirements of front fork is to have optimum structural stiffness while having lower weight so as to facilitate easy operation of the handlebar for steering the vehicle. Higher weight of the front fork leads higher steering inertia that causes undesired steering response. To meet above requirement of optimal structural stiffness and lower weight, size and thickness of the front fork inner tube is optimised to have optimum stiffness with lowest possible weight. However, such optimization that provides smaller size of the front fork, results in poor aesthetics of motorcycle as the small sized front fork does not gel with the other styling elements of the motorcycle.
[003] To allow for the small sized front fork tubes to gel with the other styling elements, front fork covers are used to cover the pair of front forks. The front fork covers allow for the pair of front forks to appear bigger while ensuring that not much weight is added. The front fork covers are usually made of steel. One major issue with the provision of the front fork covers is that under certain riding conditions, water finds its way into the front fork covers and gets accumulated inside the front fork covers. The water accumulation not only leaves the pair of front forks susceptible to water damage over time, but also give rise to unnecessary vibrations and hinderance in steering output.
[004] Conventionally, to ensure that the front fork covers are assembled in a mistake proof manner, commonly known as poka-yoke in the industry, the pair of front fork covers are connected through a stabiliser. The provision of a stabiliser not only results in an increase in part count and hampering the ease of assembly, but also means that the pair of front fork covers cannot be interchangeably used. This means that a front fork cover designed for a left front fork can only be used for the left sided front fork and the front fork cover designed for a right front fork can only be used for the right sided front fork. Such a limitation increases the manufacturing cost and cost of assembly.
[005] Thus, there is a need in the art for a front fork assembly for a saddle type vehicle, which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[006] In one aspect, the present invention is directed towards a front fork assembly for a saddle type vehicle. The assembly has a pair of front forks having a first fork tube and a second fork tube. An upper bracket connects the first fork tube with the second fork tube. A lower bracket connects the first fork tube with the second fork tube and the lower bracket is placed downwardly of the upper bracket. A front fork cover is configured for covering at least the first fork tube. Herein, the front fork cover extends between the upper bracket and the lower bracket. The front fork cover has a protrusion configured to be engaged with the upper bracket. A boot member is disposed between the lower bracket and the first fork tube. The boot member abuts the first fork tube and the front fork cover. One or more drain holes are provided on the boot member, wherein the one or more drain holes are positioned on the outside of the first fork tube and on the inside of the front fork cover.
[007] In an embodiment of the invention, the front fork cover has a first front fork cover for covering the first fork tube and a second front fork cover for covering the second fork tube.
[008] In a further embodiment of the invention, the saddle type vehicle has a pair of boot members such that one boot member is disposed between the lower bracket and the first fork tube, and other boot member disposed between the lower bracket and the second fork tube.
[009] In a further embodiment of the invention, the boot member has a tubular cross section such that an inner portion of the boot member abuts the first fork tube, and an outer portion of the boot member abuts the front fork cover.
[010] In a further embodiment of the invention, an outer diameter of the boot member is greater than an outer diameter of the front fork cover such that the boot member abuts the front fork cover on an outer surface of the front fork cover.
[011] In a further embodiment of the invention, the upper bracket has one or more slots configured to receive the protrusion on the front fork cover.
[012] In a further embodiment of the invention, the front fork cover has a cylindrical profile. The cylindrical profile of the front fork cover is configured to cover a cylindrical profile of the first fork tube or the second fork tube.

BRIEF DESCRIPTION OF THE DRAWINGS
[013] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a left side view of an exemplary saddle type vehicle, in accordance with an embodiment of the present invention.
Figure 2 illustrates a rear perspective view of a front fork assembly for the saddle type vehicle, in accordance with an embodiment of the present invention.
Figure 3 illustrates front perspective view of the front fork assembly, in accordance with an embodiment of the present invention.
Figure 4 illustrates a front sectional view of the front fork assembly, in accordance with an embodiment of the present invention.
Figure 5 illustrates a sectional view of a front fork cover and a first fork tube of the front fork assembly, in accordance with an embodiment of the present invention.
Figure 6 illustrates a sectional view of the front fork cover and an upper bracket of the front fork assembly, in accordance with an embodiment of the present invention.
Figure 7A, 7B and 7C illustrates a protrusion on the front fork cover, in accordance with an embodiment of the present invention.
Figure 8 illustrates another sectional view of a front fork cover and a first fork tube of the front fork assembly, in accordance with an embodiment of the present invention.
Figure 9 illustrates a bottom perspective view of the front fork assembly, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[014] The present invention generally relates to a saddle type vehicle. More particularly, the present invention relates to a front fork assembly for the saddle type vehicle.
[015] Figure 1 illustrates an exemplary saddle type vehicle 10, in accordance with an embodiment of the invention. The vehicle 10 includes an internal combustion engine 12 that is vertically disposed or a traction motor (not shown). Preferably, the Internal combustion engine 12 is a single-cylinder type internal combustion engine. The vehicle 10 further includes a front wheel 14, a rear wheel 16, a frame member, a seat assembly 18 and a fuel tank 40. The frame member includes a head pipe 22 (shown in Figure 2), a main frame 24, a down tube (not shown), and seat rails (not shown). The head pipe 22 supports a steering shaft (not shown) and two telescopic front fork suspensions 26 (shown in Figure 2) attached to the steering shaft through a lower bracket 130 (shown in Figure 4). The two telescopic front fork suspensions 26 support the front wheel 14. The upper portion of the front wheel 14 is covered by a front fender 28 mounted to the lower portion of the telescopic front fork suspensions 26 at the end of the steering shaft. A head light 32, a visor guard 33 and instrument cluster (not shown) are arranged on an upper portion of the head pipe 22. The frame member having the down tube (not shown) may be located in front of the internal combustion engine 12 and extends slantly downward from the head pipe 22. The main frame 24 of the frame member is located above the internal combustion engine 12 and extends rearward from the head pipe 22. The internal combustion engine 12 is mounted at the front to the down tube and a rear of the internal combustion engine 12 is mounted at the rear portion of the main frame 24. In an embodiment, the internal combustion engine 12 is mounted vertically, with a cylinder block extending vertically above a crankcase. In an alternative embodiment, the internal combustion engine 12 is mounted horizontally (not shown) with the cylinder block extending horizontally forwardly from the crankcase. In an embodiment, the cylinder block is disposed rearwardly of the down tube.
[016] The fuel tank 40 of the vehicle 10 is mounted on the main frame 24. Seat rails are joined to the main frame 24 and extend rearward to support the seat assembly 18. A rear swing arm 34 is connected to the frame member to swing vertically, and the rear wheel 16 is connected to rear end of the rear swing arm 34. Generally, the rear swing arm 34 is supported by a mono rear suspension 36 or through two suspensions (not shown) on either side of the vehicle 10. A taillight unit 37 is disposed at the end of the vehicle 10 and at the rear of the seat assembly 18. The rear wheel 16 arranged below seat 18 rotates by the driving force of the Internal combustion engine 12 transmitted through a chain drive 39 from the internal combustion engine 12. A rear fender 38 is disposed above the rear wheel 16.
[017] Further, an exhaust pipe (not shown) of the saddle type vehicle 10 extends vertically downward from the Internal combustion engine 12 up to a point and then extends below the Internal combustion engine 12, longitudinally along the vehicle length before terminating in a muffler (not shown). The muffler is typically disposed adjoining the rear wheel 16.
[018] The vehicle 10 further includes a handlebar 50 connected to the head pipe 22 of the frame member and extending in a vehicle width direction. The handlebar 50 can rotate to both sides of the vehicle 10 during vehicle turning movements.
[019] Figures 2 illustrates a front fork assembly 100 for a saddle type vehicle 10 in accordance with an embodiment of the invention. As illustrated in Figure 2 and further illustrated in Figure 3, the front fork assembly 100 has a pair of front forks. The pair of front forks have a first fork tube 112 and a second fork tube 114. In an embodiment, the first fork tube 112 is provided on the right side of the vehicle in a vehicle rear view, and the second fork tube 114 is provided on the left side of the vehicle in the vehicle rear view. The pair of front forks are connected to the front fork suspensions 26, to support the front wheel 14 of the vehicle 10.
[020] As further illustrated in Figure 3, the front fork assembly 100 has an upper bracket 120 that connects the first fork tube 112 with the second fork tube 114. The upper bracket 120 further connects the first fork tube 112 and the second fork tube 114 to the head pipe 22. The front fork assembly 100 further has the lower bracket 130 for connecting the first fork tube 112 with the second fork tube 114. The lower bracket 130 further connects the first fork tube 112 and the second fork tube 114 to the head pipe 22. Herein, the lower bracket 130 is placed downwardly of the upper bracket 120. Thus, the steering motion of the handlebar 50 mounted on the head pipe 22, is transmitted to the front wheel 14 by means of the upper bracket 120 and the lower bracket 130.
[021] The front fork assembly 100 further has a front fork cover 140. The front fork cover 140 is configured for covering at least the first fork tube 112. In that, the front fork cover 140 extends between the upper bracket 120 and the lower bracket 130. The front fork cover 140 has a protrusion 142 (shown in Figure 6) that is configured to be engaged with the upper bracket 120. The engagement of the protrusion 142 on the upper bracket 120 ensures mistake proof assembling, or otherwise known as poka-yoke of the front fork cover 140. In an embodiment, as referenced in Figure 4, the front fork cover 140 comprises a first front fork cover 140A for covering the first fork tube 112, and a second front fork cover 140B for covering the second fork tube 114. The provision of the first front fork cover 140A and the second front fork cover 140B for covering the pair of front forks ensures that the small sized front forks 112,114 are covered by larger sized front fork cover 140. Further, in an embodiment, the front fork cover 140 is made up of vehicle grade plastic. This ensures that the front forks 112, 114 gel with the other styling parts of the vehicle 10 by virtue of the front fork cover 140, while ensuring lower weight.
[022] To facilitate assembly of the front fork cover 140 on to the first fork tube 112, the front fork assembly 100 further has a boot member 150 that is disposed between the lower bracket 130 and the first fork tube 112. The boot member 150 abuts the first fork tube 112 and the front fork cover 140, thereby assembling the front fork cover 140 on to the first fork tube 112. In an embodiment, the front fork assembly 100 has a pair of boot members 150 such that one boot member 150A (shown in Figure 4) is disposed between the lower bracket 130 and the first fork tube 112, and other boot member 150B (shown in Figure 4) disposed between the lower bracket 130 and the second fork tube 114.
[023] To address the issue of water accumulation inside the front fork cover 140, the front fork assembly 100 further has one or more drain holes 152 (shown in Figure 8 and Figure 9) provided on the boot member 150. The one or more drain holes 152 are positioned on the outside of the first fork tube 112 and on the inside of the front fork cover 140. Thus, any water or dust accumulated between first fork tube 112 and the front fork cover 140, assisted by gravity, is drained out from the drain holes 152. In an embodiment, one or more drain holes 152 are provided on the boot member 150A, on the outside of the first fork tube 112 and on the inside of the first front fork cover 140A. Similarly, one or more drain holes 152 are provided on the other boot member 150B, on the outside of the second fork tube 114 and on the inside of the second front fork cover 140B.
[024] As illustrated in Figure 5, in an embodiment, the boot member 150 has a tubular cross section such that an inner portion 150I of the boot member 150 abuts the first fork tube 112 and an outer portion 150O of the boot member 150 abuts the front fork cover 140. To ensure assembly of the front fork assembly 100 in a tight fit manner, an outer diameter of the boot member 150 is greater than an outer diameter of the front fork cover 140, such that the boot member 150 abuts the front fork cover 140 on an outer surface of the front fork cover 140. This means that the boot member 150 presses on to the outer surface of the front fork cover 140, pushing the front fork cover 140 inside towards the first fork tube 112.
[025] As mentioned earlier, and as further illustrated in Figures 7A, 7B and 7C, to ensure mistake proof assembling or poka-yoke, the front fork cover 140 has the protrusion 142 that is configured to be engaged with the upper bracket 120. In that, the upper bracket 120 has one or more slots configured to receive the protrusion 142 on the front fork cover 140. In an embodiment, the first front fork cover 140A and the second front fork cover 140B comprise the protrusion 142 which engage with the one or more slots on the upper bracket 120.
[026] As illustrated in Figure 8, in an embodiment, the front fork cover 140 has a cylindrical profile. The cylindrical profile of the front fork cover 140 is configured to cover a cylindrical profile of the first fork tube 112 or the second fork tube 114. In an embodiment, the first front fork cover 140A and the second front fork cover 140B have a cylindrical profile, to respectively cover the first fork tube 112 and the second fork tube 114.
[027] Advantageously, the present invention provides a saddle type vehicle in which the front fork cover is provided so as to allow for a lower weight and smaller sized pair of front forks to be used, without compromising with the aesthetics of the saddle type vehicle. Further, provision of the one or more drain holes ensures that water and dust is not accumulated inside the front fork cover, thus ensuring that the pair of front forks is protected against water damage and steering interference due to water ingress.
[028] Further, for mistake proof assembling or poka-yoke, protrusions are provided on the front fork cover which engage with the upper bracket, which eliminates the requirement of any stabiliser to be connected between the pair of front forks. This not only reduces the part count, but also improves ease of manufacturing and assembly.
[029] Further, since there is no requirement of a stabiliser between the pair of front forks also means that the first front fork cover and the second front fork cover can be used interchangeably, that is first front fork cover can be used to cover the second fork tube and the second front fork cover can be used to cover the first fork tube, thus easing out the manufacturing process and the associated costs.
[030] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
 
, Claims:WE CLAIM:
1. A front fork assembly (100) for a saddle type vehicle (10), comprising:
a pair of front forks having a first fork tube (112) and a second fork tube (114);
an upper bracket (120) for connecting the first fork tube (112) with the second fork tube (114);
a lower bracket (130) for connecting the first fork tube (112) with the second fork tube (114), the lower bracket (130) being placed downwardly of the upper bracket (120);
a front fork cover (140) configured for covering at least the first fork tube (112), the front fork cover (140) extending between the upper bracket (120) and the lower bracket (130), the front fork cover (140) having a protrusion (142) configured to be engaged with the upper bracket (120);
a boot member (150) disposed between the lower bracket (130) and the first fork tube (112), the boot member (150) abutting the first fork tube (112) and the front fork cover (140); and
one or more drain holes (152) provided on the boot member (150), the one or more drain holes (152) being positioned on the outside of the first fork tube (112) and on the inside of the front fork cover (140).

2. The front fork assembly (100) as claimed in claim 1, wherein the front fork cover (140) comprises a first front fork cover (140A) for covering the first fork tube (112) and a second front fork cover (140B) for covering the second fork tube (114).

3. The front fork assembly (100) as claimed in claim 1, comprising a pair of boot members (150) such that one boot member (150A) is disposed between the lower bracket (130) and the first fork tube (112) and other boot member (150B) disposed between the lower bracket (130) and the second fork tube (114).

4. The front fork assembly (100) as claimed in claim 1, wherein the boot member (150) has a tubular cross section such that an inner portion (150I) of the boot member (150) abuts the first fork tube (112) and an outer portion (150O) of the boot member (150) abuts the front fork cover (140).

5. The front fork assembly (100) as claimed in claim 4, wherein an outer diameter of the boot member (150) is greater than an outer diameter of the front fork cover (140) such that the boot member (150) abuts the front fork cover (140) on an outer surface of the front fork cover (140).

6. The front fork assembly (100) as claimed in claim 1, wherein the upper bracket (120) comprises one or more slots configured to receive the protrusion (142) on the front fork cover (140).

7. The front fork assembly (100) as claimed in claim 1, wherein the front fork cover (140) has a cylindrical profile, the cylindrical profile of the front fork cover (140) configured to cover a cylindrical profile of the first fork tube (112) or the second fork tube (114).