Claims:WE CLAIM:
1. A kickstart system (100) for a saddle type vehicle (10), comprising:
a kickstart shaft (110) extending in a vehicle width direction, the kickstart shaft (110) having a first end (110A) and a second end (110B), the first end (110A) of the of the kickstart shaft (110) having a plurality of external splines (112) wherein at least two consecutive external splines (112) are joint to define a protrusion (114); and
a kickstart lever (120) configured to be detachably connected to the first end (110A) of the kickstart shaft (110), the kickstart lever (120) having a slot with a plurality of internal splines (122) wherein at least two consecutive internal splines (122) are joint to define a recess (124) configured for receiving the protrusion (114) on the first end (110A) of the kickstart shaft (110).

2. The kickstart system (100) as claimed in claim 1, comprising a drive gear (130) connected at the second end (110B) of the kickstart shaft (110) and meshed with a driven gear (150), the drive gear (130) having at least one resting tooth (132) for limiting the rotation of the drive gear (130) wherein the resting tooth (132) is oriented at a predetermined angle (X) with respect to the protrusion (114), thereby controlling a resting position of the kickstart lever (120).

3. The kickstart system (100) as claimed in claim 1, wherein the resting tooth (132) on the drive gear (130) is formed by joining at least two adjacent teeth on the drive gear (130).

4. The kickstart system (100) as claimed in claim 1, wherein the kickstart lever (120) is configured to be in the resting position when the resting tooth (132) is in contact with the driven gear (150).

5. The kickstart system (100) as claimed in claim 4, comprising a return spring (140) such that the return spring (140) is loaded when the kickstart lever (120) is rotated by a user, and on release of the kickstart lever (120), the return spring (140) is configured to bring the kickstart lever (120) to the resting position where the resting tooth (132) is in contact with the driven gear (150).

6. The kickstart system (100) as claimed in claim 1, comprising a cover variator (160) disposed inwardly of the kickstart lever (120) in the vehicle width direction, the cover variator (160) configured for supporting the kickstart shaft (110).

7. The kickstart system (100) as claimed in claim 6, comprising a bush (162) for supporting the kickstart shaft (110) on the cover variator (160).

8. The kickstart system (100) as claimed in claim 6, comprising a kickstart cover (170) configured to be attached with the cover variator (160) defining an enclosed space therein, the kickstart shaft (110) being disposed in the enclosed space.

9. The kickstart system (100) as claimed in claim 8, wherein the kickstart cover (170) is configured for supporting the driven gear (150).

10. A saddle type vehicle (10), comprising:
a kickstart shaft (110) extending in a vehicle width direction, the kickstart shaft (110) having a first end (110A) and a second end (110B), the first end (110A) of the of the kickstart shaft (110) having a plurality of external splines (112) wherein at least two consecutive external splines (112) are joint to define a protrusion (114);
a kickstart lever (120) configured to be detachably connected to the first end (110A) of the kickstart shaft (110), the kickstart lever (120) having a slot with a plurality of internal splines (122) wherein at least two consecutive internal splines (122) are joint to define a recess (124) configured for receiving the protrusion (114) on the first end (110A) of the kickstart shaft (110); and
a drive gear (130) connected at the second end (110B) of the kickstart shaft (110) and meshed with a driven gear (150), the drive gear (130) having at least one resting tooth (132) for limiting the rotation of the drive gear (130) wherein the resting tooth (132) is oriented at a predetermined angle (X) with respect to the protrusion (114), thereby controlling a resting position of the kickstart lever (120) such that resting position of the kickstart lever (120) is at a predetermined distance from a centre stand lever (182) of a centre stand (180), when the centre stand (180) is in a stand off condition.

11. A method (200) of manufacturing a kickstart system (100) for a saddle type vehicle (10), the method (200) comprising the steps of:
forming a plurality of external splines (112) on a first end (110A) of a kickstart shaft (110);
providing at least two consecutive external splines (112) that are joint, thereby defining a protrusion (114) on the first end (110A) of the kickstart shaft (110);
forming a plurality of internal splines (122) on a slot on a kickstart lever (120) configured to receive the first end (110A) of the kickstart shaft (110);
providing at least two consecutive internal splines (122) that are joint, thereby defining a recess (124) configured to receive the protrusion (114);
forming at least one resting tooth (132) on a drive gear (130) by joining at least two consecutive gear teeth; and
fixedly attaching the drive gear (130) to a second end (110B) of the kickstart shaft (110), such that orientation of the resting tooth (132) is at a predetermined angle (X) with respect to the protrusion (114) on the first end (110A) of the kickstart shaft (110), thereby controlling a resting position of the kickstart lever (120).
, Description:FIELD OF THE INVENTION
[001] The present invention relates to a kickstart system for a saddle type vehicle and a method of manufacturing thereof.

BACKGROUND OF THE INVENTION
[002] In conventional saddle type vehicle, single-stage kickstart systems are preferred as the dual-stage kickstart systems have safety related drawbacks as the riders are allowed to kickstart even when the vehicle is not in on-stand condition. In contrast, in case of single-stage kickstart system, the same can be activated only when the centre stand is in on condition. Thus, the single-stage kickstart system is considered safer as compared to the dual-stage kickstart system.
[003] In the existing single-stage kickstart mechanisms, the kick lever, pillion foot rest and centre stand lever are placed very close to each other. Thus, even though the kick lever is disposed rearwardly towards the vehicle rear side to minimize safety related risks, the positioning of the kickstart lever sandwiched between the lady pillion footrest and the centre stand lever even in off-stand condition can lead to interference issues. The kickstart lever tends to interfere with the centre stand lever and thus, such intrusion needs to be minimized.
[004] An additional issue in the existing mechanisms is that, with the increasing length of centre stand, the centre stand lever comes in the proximity of kickstart lever. Since the kick lever’s resting position is determined by the positioning of resting tooth on the gear drive, a variability is introduced in the kick lever’s position. The kick lever is generally mounted onto a plurality of splines on a shaft. The kick shaft has external splines, and the kick lever has internal splines. Thus, the spline coupling allows for multiple positions for the kickstart lever’s assembly. The multiple positions increase the chances of hindrance between kickstart lever and the centre stand when the kick lever has been mounted on the shaft in an undesirable position. This results in a situation wherein the variability is very high, which can result into a position of the kick lever that is not ergonomically ideal.
[005] Thus, there is a need in the art for a kickstart system for a saddle type vehicle which addresses the aforementioned problems.

SUMMARY OF THE INVENTION
[006] In an aspect, the present invention is directed towards a kickstart system for a saddle type vehicle. The kickstart system has a kickstart shaft extending in a vehicle width direction, and the kickstart shaft have a first end and a second end. The first end of the of the kickstart shaft have a plurality of external splines where at least two consecutive external splines are joint to define a protrusion. The system further has a kickstart lever configured to be detachably connected to the first end of the kickstart shaft and the kickstart lever is having a slot with a plurality of internal splines wherein at least two consecutive internal splines are joint to define a recess which is configured for receiving the protrusion on the first end of the kickstart shaft.
[007] In an embodiment of the invention, the kickstart system further has a drive gear connected at the second end of the kickstart shaft and is meshed with a driven gear. The drive gear has at least one resting tooth for limiting the rotation of the drive gear wherein the resting tooth is oriented at a predetermined angle with respect to the protrusion and thereby it controls a resting position of the kickstart lever.
[008] In an embodiment of the invention, the resting tooth on the drive gear is formed by joining at least two adjacent teeth on the drive gear.
[009] In another embodiment of the invention, the kickstart lever is configured to be in a first resting position when the resting tooth is in contact with the driven gear.
[010] In a further embodiment of the invention, the kickstart system has a return spring such that the return spring is loaded when the kickstart lever is rotated by a user, and on release of the kickstart lever, the return spring is configured to bring the kickstart lever to the first resting position where the resting tooth is in contact with the driven gear.
[011] In a further embodiment of the invention, a cover variator is disposed inwardly of the kickstart lever in the vehicle width direction and the cover variator is configured for supporting the kickstart shaft.
[012] In a further embodiment of the invention, a bush is placed for supporting the kickstart shaft on the cover variator.
[013] In a further embodiment of the invention, a kickstart cover is configured to be attached with the cover variator defining an enclosed space therein and the kickstart shaft is being disposed in the enclosed space.
[014] In a further embodiment of the invention, the kickstart cover is configured for supporting the driven gear.
[015] In a further embodiment of the invention, the first resting position of the kickstart lever is at a predetermined distance from a centre stand lever of a centre stand and when the centre stand is in a stand off condition.
[016] In another aspect, the present invention relates to a saddle type vehicle. The saddle type vehicle has a kickstart shaft extending in a vehicle width direction, and the kickstart shaft have a first end and a second end. The first end of the of the kickstart shaft have a plurality of external splines where at least two consecutive external splines are joint to define a protrusion. The vehicle further has a kickstart lever configured to be detachably connected to the first end of the kickstart shaft and the kickstart lever is having a slot with a plurality of internal splines wherein at least two consecutive internal splines are joint to define a recess which is configured for receiving the protrusion on the first end of the kickstart shaft. Further, the vehicle has a drive gear connected at the second end of the kickstart shaft and is meshed with a driven gear. The drive gear has at least one resting tooth for limiting the rotation of the drive gear wherein the resting tooth is oriented at a predetermined angle (X) with respect to the protrusion and thereby it controls a resting position of the kickstart lever.
[017] In another aspect, the present invention relates to a method of manufacturing a kickstart system for a saddle type vehicle. The method has the steps of: forming a plurality of external splines on a first end of a kickstart shaft; providing at least two consecutive external splines that are joint, thereby defining a protrusion on the first end of the kickstart shaft; forming a plurality of internal splines on a slot on a kickstart lever configured to receive the first end of the kickstart shaft; providing at least two consecutive internal splines that are joint, thereby defining a recess configured to receive the protrusion; forming at least one resting tooth on a drive gear by joining at least two consecutive gear teeth; and fixedly attaching the drive gear to a second end of the kickstart shaft, such that orientation of the resting tooth is at a predetermined angle with respect to the protrusion on the first end of the kickstart shaft, thereby controlling a resting position of the kickstart lever.

BRIEF DESCRIPTION OF THE DRAWINGS
[018] 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 invention.
Figure 2 illustrates a left side view of a kickstart system of the vehicle, in accordance with an embodiment of the invention.
Figure 3 illustrates another side view of the kickstart system, in accordance with an embodiment of the invention.
Figure 4 illustrates an exploded perspective view of the kickstart system, in accordance with an embodiment of the invention.
Figure 5 illustrates a perspective view of the kickstart system, in accordance with an embodiment of the invention.
Figure 6a and 6b illustrate a perspective view of a kickstart shaft and a drive gear respectively, in accordance with an embodiment of the invention.
Figure 7a and 7b illustrate a perspective view of the kickstart shaft and the kickstart lever respectively, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[019] In an aspect, the present invention relates to a kickstart system of a vehicle. More particularly, the present invention relates to a kickstart system for a saddle type vehicle and a method of manufacturing thereof.
[020] Figure 1 illustrates a left-side view of an exemplary motor vehicle 10, in accordance with an embodiment of the present subject matter. The vehicle 10 comprises a frame (not shown). The frame comprises a head tube, and a portion of a main tube extending rearwardly downward from the head tube to a floorboard 18. One or more front suspensions 44 connect a front wheel 14 to a handlebar 20, which forms a steering assembly of the vehicle 10. The steering assembly is rotatably disposed about the head tube. The main tube further includes a portion extending horizontally and rearwardly from the frame. Further, the frame includes one or more rear tubes extending inclinedly rearward from a rear portion of the main tube towards a rear portion of the vehicle 10.
[021] The vehicle 10 includes a power unit comprising at least an internal combustion (IC) engine 12. The power unit is coupled to a rear wheel 16. In one embodiment, the engine (not shown) is swingably connected to the frame. In one embodiment, the engine 12 is mounted to the swing arm (not shown) and the swing arm is swingably connected to the frame. Further, the vehicle 10 includes a transmission means (not shown) coupling the rear wheel 16 to the power unit. The transmission means includes a continuously variable transmission, an automatic transmission, or a fixed ratio transmission. A seat assembly 22 is disposed above the engine 12 and is supported by the rear tubes of the frame. The seat assembly 22 is hingedly openable. The frame defines a step-through portion ahead of the seat assembly 22. The floorboard 18 is disposed at the step-through portion, wherein a rider can operate the vehicle 10 in a seated position by resting feet on the floorboard 18. Further, the floorboard 18 is capable of carrying loads.
[022] Further, the frame is covered by plurality of body panels including a front panel 30 having a front face 30A and a rear face 30B, an under-seat cover 32, and a left and a right-side panel 33 disposed on the frame and covering the frame and parts mounted thereof.
[023] In addition, a front fender 24 is covering at least a portion of the front wheel 14. A utility box (not shown) is disposed below the seat assembly 22 and is supported by the frame. A rear fender 26 is covering at least a portion of the rear wheel 16 and is positioned upwardly of the rear wheel 16. One or more suspension(s) 46 are provided in the rear portion of the vehicle 10 for connecting the swing arm and the rear wheel 16 to the frame for damping the forces from the rear wheel 16 and the engine (not shown) from reaching the frame.
[024] Furthermore, the vehicle 10 comprises of plurality of electrical and electronic components including a headlight 36, a taillight 38, an alternator (not shown), and a starter motor (not shown).
[025] Figure 2 illustrates a left side view of a kickstart system 100 mounted on the saddle type vehicle 10. In the embodiment depicted in Figure 2 and Figure 3, the kickstart system 100 comprises a kickstart lever 120. The kickstart lever is configured to be actuated by a user for starting the engine 12 of the vehicle 10.
[026] As illustrated in Figure 4 and Figure 5, the kickstart system 100 has a kickstart shaft 110. The kickstart shaft 110 has a first end 110A and a second end 110B. The first end 110A of the kickstart shaft 110 has a plurality of external splines 112. The plurality of external splines 112 are a set of narrow keys formed longitudinally around the circumference of the first end 110A of the kickstart shaft 110 that are configured to mate with and fit into corresponding grooves or splines. In that, at least two consecutive external splines 112 are joint to define a protrusion 114 (shown in Figure 7a).
[027] As further illustrated in Figure 5, the kickstart system 100 has the kickstart lever 120 which is configured to be detachably connected to the first end 110A of the kickstart shaft 110. To facilitate the detachable connection of the kickstart lever 120 to the first end 110A of the kickstart shaft 110, the kickstart lever 120 has a slot with a plurality of internal splines 122. The plurality of internal splines 122 are a set of narrow keys formed longitudinally on an inner surface of the slot of the kickstart lever 120, that are configured to mate with the plurality of external splines 112. Herein, at least two consecutive internal splines 122 are joint to define a recess 124 (also shown in Figure 7b). The recess 124 is configured for receiving the protrusion 114 on the first end 110A of the kickstart shaft 110. The provision of the protrusion 114 on the first end 110A of the kickstart shaft 110 and the recess 124 on the kickstart lever 120 ensures that the kickstart lever 120 can be connected to the kickstart shaft 110 at only one position, as opposed to multiple positions that are allowed by conventional internal and external splines.
[028] As further illustrated in the Figure 4 and Figure 5, the kickstart system 100 has a drive gear 130 that is connected at the second end 110B of the kickstart shaft 110. The drive gear 130 is meshed with a driven gear 150, which is then connected to the crankshaft of the engine. Therefore, actuation of the kickstart lever 120 causes the kickstart shaft 110 to rotate, which causes the drive gear 130 to rotate. Rotation of the drive gear 130 thereafter causes the rotation of the driven gear 150, which effects rotation of the crankshaft for starting the engine 12.
[029] In an embodiment, the drive gear 130 has at least one resting tooth 132 for limiting the rotation of the drive gear 130. The resting tooth 132 is formed by joining at least two consecutive gear teeth on the drive gear 130, such that the resting tooth 132 cannot mesh with the driven gear 150. As soon as the resting tooth 132 comes in contact with the driven gear 150, the drive gear 130 cannot further mesh with the driven gear 150, and hence the rotation of the drive gear 130 is limited. Reference is made to Figure 6b and Figure 7a, wherein, the resting tooth 132 is oriented at a predetermined angle (X) with respect to the protrusion 114. The orientation of the protrusion 114 with respect to the resting tooth 132, and the kickstart lever 120 being connected to the kickstart lever 110 at a singular position, thus determines a resting position of the kickstart lever 120.
[030] In the present invention, the resting tooth 132 and the protrusion 114 are oriented such that the kickstart lever 120 is in a resting position when the resting tooth 132 is in contact with the driven gear 150. The resting position is configured such that the kickstart lever 120 is at a substantial distance from a pillion footrest 42, thereby preventing any interference of the kickstart lever 120 with the pillion footrest 42.
[031] Further, as referenced in Figure 1, the resting position of the kickstart lever 120 is configured such that the kickstart lever 120 is at a predetermined distance from a centre stand lever 182 of a centre stand 180, when the centre stand 180 is in a stand off condition. This prevents any interference from the centre stand lever 182. In an embodiment, the centre stand 180 is swingably mounted onto crankcase (not shown) and the centre stand lever 182 extends from the centre stand 180 and is mated to it at a rotatable joint.
[032] Reference is made to Figure 4, wherein as illustrated, the kickstart system 100 further has a return spring 140 connected to the kickstart shaft 110. The return spring 140 is connected such that the return spring 140 is loaded when kickstart shaft is 110 is rotated via the kickstart lever 120 by a user. On release of the kickstart lever 120, the return spring 140 is configured to get unloaded and bring the kickstart lever 120 to the resting position where the resting tooth 132 is in contact with the driven gear 150.
[033] As further illustrated in Figure 4, the kickstart system 100 further has a cover variator 160 disposed inwardly of the kickstart lever 120 in the vehicle width direction. The cover variator 160 is configured for supporting the kickstart shaft 110. The cover variator 160 also covers the kickstart system 100 and encloses the different kick gears. In an embodiment, the kickstart system 100 further has a bush 162 for supporting the kickstart shaft 110 on the cover variator 160.
[034] As further illustrated in Figure 4, the kickstart system 100 further has a kickstart cover 170 that is configured to be attached with the cover variator 160. The kickstart cover 170 and the cover variator 160 define an enclosed space, and the kickstart shaft 110 is disposed in the enclosed space. In an embodiment, the kickstart cover 170 is also configured for supporting the driven gear 150.
[035] In another aspect, the present invention relates to a saddle type vehicle 10 comprising a kickstart shaft 110, a kickstart lever 120 and a drive gear 130 explained as hereinbefore.
[036] In another aspect, the present invention relates to a method 200 of manufacturing a kickstart system 100 for a saddle type vehicle. Figure 8 illustrates the method steps involved in manufacturing of the kickstart system 100. At step 2A, a plurality of external splines 112 are formed on a first end 110A of a kickstart shaft 110. At step 2B, at least two consecutive external splines 112 that are joint are provided, thereby defining a protrusion 114 on the first end 110A of the kickstart shaft 110. At step 2C, a plurality of internal splines 122 are provided on a slot on a kickstart lever 120. The plurality of internal splines 122 are configured to receive the first end 110A of the kickstart shaft 110. At step 2D, at least two consecutive internal splines 122 that are joint are provided, thereby defining a recess 124 configured to receive the protrusion 114. At step 2E, at least one resting tooth 132 is formed on a drive gear 130 by joining at least two consecutive gear teeth.
[037] At step 2F, the drive gear 130 is fixedly attached to a second end 110B of the kickstart shaft 110, such that orientation of the resting tooth 132 is at a predetermined angle (X) with respect to the protrusion 114 on the first end 110A of the kickstart shaft 110, thereby controlling a resting position of the kickstart lever 120.
[038] Advantageously, the present invention provides a kickstart system in which the kickstart lever is disposed with respect to the pillion footrest and the centre stand lever a predetermined position, such that the pillion foot rest and the centre stand lever do not hinder with the kickstart lever, thereby providing a kickstart system that is ergonomically ideal and is easier to assemble.
[039] Further, the present invention also ensures better aesthetics for the vehicle as the alignments of one component do not hinder or overlaps the other. Furthermore, by the improved positioning of kickstart assembly and the centre stand, it eases the handling of vehicle, thereby improving riders’ comfort.
[040] 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.