Description:

FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]

BODY FRAME OF VEHICLE

HERO MOTOCORP LIMITED, an Indian Company at: The Grand Plaza, Plot No.2, Nelson Mandela Road, Vasant Kunj- Phase -II, New Delhi, India, 110 070

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD OF THE INVENTION:
[001] The present invention relates to body frame structure and a stay structure of a vehicle. The invention further provides a vehicle incorporating the particular body frame structure and the particular stay structure. The invention further discloses a method for assembling a fuel tank on a vehicle.

BACKGROUND OF THE INVENTION:
[002] A vehicle generally comprises multiple vehicular parts that are assembled together in a non-interfering manner. Thus, a lot of emphasis is placed on the aspect of the non-interference, when designing each of the multiple parts.

[003] It should be noted that despite designing each of the multiple parts in a manner that they are non-interfering with each other in assembled state, there may arise a situation where the one or more vehicular parts interferes with one or more other vehicular parts during an assembling process or during a dismantling process. Furthermore, a lot of emphasis is placed on the aspect of a time needed to assemble the parts and a time needed to dismantle the parts.

[004] Especially in a vehicle having a body frame structure carrying plurality of other vehicular parts, designing each of the vehicular parts becomes a complication as multiple criteria have to be simultaneously satisfied. Thus, there exists a need to address one or more of the aforesaid problems.

SUMMARY OF THE INVENTION:
[005] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features.

[006] In one aspect of the invention, there is provided a body frame structure of a vehicle. The body frame structure comprises a head pipe; a main frame attached to the head pipe so as to extend in a down-ward and rear-ward direction of the vehicle; a first cross bar attached to a free end of the main frame; a right rear rail and a left rear rail extending from the first cross bar in a rear-ward and up-ward direction of the vehicle; and a stay structure detachably attached to the right rear rail and the left rear rail.

[007] In an embodiment of the invention, the right rear rail comprises a first attachment part for detachably attaching the stay structure and the left rear rail comprises a second attachment part for detachably attaching the stay structure.

[008] In another embodiment of the invention, the right rear rail comprises at least a first hanger part for hanging the stay structure and the left rear rail comprises at least a second hanger part for hanging the stay structure.

[009] In yet another embodiment of the invention, the body frame structure comprises a second cross plate attached between the right rear rail and the left rear rail.

[0010] In still another embodiment of the invention, the second cross plate comprises a third attachment part and a fourth attachment part for detachably attaching the stay structure.

[0011] In a further embodiment of the invention, the second cross plate comprises a third hanger part and a fourth hanger part for hanging the stay structure.

[0012] In another aspect of the invention, there is provided a stay structure of a vehicle. The stay structure co-operates with a right rear rail and a left rear rail for holding at least a fuel tank and a rear fender of the vehicle. In accordance with an embodiment of the invention, said stay structure comprises a body portion defining a first leg and a second leg spaced apart from each other, the first leg including a first proximal portion and a first distal portion, and the second leg including a second proximal portion and a second distal portion, the first distal portion being connected to the second distal portion to form a substantially V or U shape; the first proximal portion comprising a first attachment part for attaching the stay structure to the right rear rail; and the second proximal portion comprising a second attachment part for attaching the stay structure to the left rear rail.

[0013] In an embodiment of the invention, the first attachment part comprises a first set of attachment means and the second attachment part comprises a second set of attachment means, the first set of attachment means and the second set of attachment means being adapted to attach the stay structure to the right rear rail and the left rear rail, respectively.

[0014] In another embodiment of the invention, the first attachment part comprises a third set of attachment means and the second attachment part comprises a fourth set of attachment means, the third set of attachment means and the fourth set of attachment means being adapted to attach the stay structure to the fuel tank.

[0015] In yet another embodiment of the invention, the body portion comprises a fifth set of attachment means for attaching the stay structure to the rear fender.

[0016] In still another embodiment of the invention, the first attachment part comprises a first hanger portion for hanging the stay structure to the right rear rail rear frame and the second attachment part comprises a second hanger portion for hanging the stay structure to the left rear rail.

[0017] In yet another aspect of the invention, there is provided a vehicle, comprising: a power unit; a front ground engaging member, and a rear ground engaging member deriving power from the power unit; a fuel tank coupled to a body frame structure of the vehicle; the body frame structure comprising: a head pipe; a main frame attached to the head pipe so as to extend in a down-ward and rear-ward direction of the vehicle; a first cross bar attached to a free end of the main frame; a right rear rail and left rear rail extending from the first cross bar in a rear-ward and up-ward direction of the vehicle; and a stay structure detachably attached to the right rear rail and the left rear rail.

[0018] In still another aspect of the invention, there is provided a method of assembling a fuel tank on a vehicle, said method comprising coupling the fuel tank to a stay structure, a rear fender, a right rear rail, and a left rear rail provided in a vehicle; wherein, at least two of the fuel tank, the rear fender, and the stay structure are coupled to form a sub-assembly and the said sub-assembly is coupled to the right rear rail and the left rear rail.

[0019] In an embodiment of the invention, the method of assembling comprises:
a. coupling the stay structure and fuel tank to obtain a first sub-assembly.;
b. coupling the first sub-assembly to the right rear rail and the left rear rail so as to obtain a first intermediate vehicle body part; and
c. coupling the rear fender to the first intermediate vehicle body.

[0020] In another embodiment of the invention, the method of assembling comprises:
a. coupling the stay structure and fuel tank to obtain the first sub-assembly;
b. coupling the first sub-assembly to the rear fender so as to obtain a second sub-assembly; and
c. coupling the second sub-assembly to the right rear rail and the left rear rail.

[0021] In yet another embodiment of the invention, the method of assembling comprises:
a. coupling the stay structure and rear fender to obtain a third sub-assembly;
b. coupling the third sub-assembly to the fuel tank to obtain the second sub-assembly; and
c. coupling the second sub-assembly to the right rear rail and the left rear rail.

[0022] In still another embodiment of the invention, the method of assembling comprises:
a. coupling the fuel tank and the rear fender to obtain a fourth sub-assembly;
b. coupling the fourth sub-assembly to the stay structure to obtain the second sub-assembly; and
c. coupling the second sub-assembly to the right rear rail and the left rear rail.

[0023] In a further embodiment of the invention, the method of assembling comprises:
a. coupling the fuel tank and the rear fender to obtain the fourth sub-assembly;
b. coupling the fourth sub-assembly to the right rear rail and the left rear rail to obtain a second intermediate vehicle body part; and
c. coupling the stay structure to the second intermediate vehicle body part.

[0024] In a furthermore embodiment of the invention, the method of assembling comprises:
a. coupling the fuel tank, the rear fender, and the stay structure to obtain the second sub-assembly;
b. coupling the second sub-assembly to the right rear rail and the left rear rail.

[0025] In an embodiment of the present invention, the method of assembling comprises:
a. coupling the first sub-assembly to the body frame structure by fastening an oval shaped aperture of the fuel tank with the attachment means ; and
b. coupling the first sub-assembly to the right rear rail and the left rear rail of the stay structure by pulling the first sub-assembly in rear direction of the vehicle and followed by pushing the first sub-assembly in a forward direction of the vehicle that enables the first sub-assembly to remain in hanged state for completion of further assembling without need of any operator.

[0026] One advantage of the invention is that the method of assembling the fuel tank to the vehicle is substantially easy. In particular, it is possible to separately create a sub-assembly that comprises at least two of the fuel tank, the rear fender, and the stay structure and then couple the sub-assembly to the body frame structure. Another advantage of the invention is that the method of dismantling the fuel tank from the vehicle is substantially eased.

[0027] To further clarify the advantages and features of the invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES:
[0028] In order that the invention may be readily understood and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying drawings, where like reference numerals refer to identical or functionally similar elements throughout the separate views. The figures together with a detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, in accordance with the present invention where:

[0029] Figure 1 illustrates a side view of an exemplary vehicle, in accordance with an embodiment of the present invention;

[0030] Figure 2 illustrates a top view of an exemplary body frame structure, in accordance with an embodiment of the present invention;

[0031] Figure 3 illustrates a side view of the body frame structure shown in Figure 2, in accordance with an embodiment of the present invention;

[0032] Figure 4 illustrates a perspective view of the body frame structure shown in Figure 2, in accordance with an embodiment of the present invention;

[0033] Figure 5 illustrates a top view of another exemplary body frame structure, in accordance with another embodiment of the present invention;

[0034] Figure 6 illustrates a perspective of the body frame structure shown in Figure 5, in accordance with another embodiment of the present invention;

[0035] Figure 7 illustrates a top view of yet another exemplary body frame structure, in accordance with yet another embodiment of the present invention;

[0036] Figure 8 illustrates a perspective of the body frame structure shown in Figure 7, in accordance with yet another embodiment of the present invention;

[0037] Figure 9 illustrates a perspective view of a stay structure, in accordance with an embodiment of the present invention;

[0038] Figure 10 illustrates a top view of the stay structure shown in Figure 6, in accordance with an embodiment of the present invention;

[0039] Figure 11 illustrates a perspective view of a fuel tank in a coupled state, in accordance with an embodiment of the present invention;

[0040] Figure 12 illustrates a method of coupling a stay structure to a fuel tank, in accordance with an embodiment of the present invention;

[0041] Figure 13 illustrates a perspective view of a first sub-assembly, in accordance with an embodiment of the present invention;

[0042] Figure 14 illustrates a method of coupling the first sub-assembly to the right rear rail and the left rear rail, in accordance with an embodiment of the present invention;

[0043] Figure 15 illustrates a side view of a first intermediate vehicle body part, in accordance with an embodiment of the present invention;

[0044] Figure 16 illustrates a method of coupling a rear fender to the first intermediate vehicle body part, in accordance with an embodiment of the present invention;

[0045] Figure 17 illustrates a method of coupling a rear fender, a stay structure, and a fuel tank to obtain a second sub-assembly, in accordance with an embodiment of the present invention;

[0046] Figure 18 illustrates a perspective view of the second sub-assembly, in accordance with an embodiment of the present invention;

[0047] Figure 19 illustrates a method of coupling the second sub-assembly to the right rear rail and the left rear rail, in accordance with an embodiment of the present invention;

[0048] Figure 20 illustrates a method of coupling the stay structure and the rear fender to obtain a third sub-assembly, in accordance with an embodiment of the present invention;

[0049] Figure 21 illustrates a perspective view of the third sub-assembly, in accordance with an embodiment of the present invention;

[0050] Figure 22 illustrates a method of coupling the fuel tank and the rear fender to obtain a fourth sub-assembly, in accordance with an embodiment of the present invention; and

[0051] Figure 23 illustrates a perspective view of the fourth sub-assembly, in accordance with an embodiment of the present invention.

[0052] It may be noted that to the extent possible, like reference numerals have been used to represent like elements in the drawings. Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help to improve understanding of aspects of the present invention. Furthermore, one or more elements may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

Detailed Description of the Invention:
[0053] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0054] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the invention and are not intended to be restrictive thereof.

[0055] As used in the description herein and throughout the claims that follow, the meaning of “a”, “an” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0056] Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment”, “in another embodiment”, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0057] The terms "comprises", "comprising", or any other variations thereof, are intended to cover anon-exclusive inclusion, such that one or more devices or sub-systems or elements or structures or components proceeded by "comprises... a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

[0058] As used herein, and unless the context dictates otherwise, the terms "coupled to", “connected to”, “operably connected to”, and “operatively connected to” are intended to include both direct connection / coupling (in which two elements that are coupled / connected to each other contact each other) and indirect coupling / connection (in which at least one additional element is located between the two elements).Therefore, the terms "coupled to" and "coupled with" are used synonymously. Similarly, the terms “connected to” and “connected with” are used synonymously.

[0059] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one ordinary skilled in the art to which this invention belongs. The device, methods, and examples provided herein are illustrative only and not intended to be limiting.

[0060] The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention. No language in the specification should be construed as indicating any non-mentioned element as being essential to the practice of the invention.

[0061] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used.

[0062] While the present invention is illustrated in the context of a vehicle, however, cover and aspects and features thereof can be used with other types of vehicles as well. The terms “vehicle”, “two wheeled vehicle” and “motorcycle” have been interchangeably used throughout the description. The term “vehicle” comprises vehicles such as motorcycles, scooters, bicycles, mopeds, scooter type vehicles, All-Terrain Vehicles (ATV) and the like.

[0063] The terms “front / forward”, “rear / rearward / back / backward”, “up / upper / top”, “down / lower / lower ward / downward, bottom”, “left / leftward”, “right / rightward” used therein represents the directions as seen from a vehicle driver sitting astride and these directions are referred by arrows Fr, Rr, U, Lr, L, R in the Figures.

[0064] Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

[0065] Referring to Figure 1, there is illustrated a vehicle (10) that comprises a front end structure (12), a rear end structure (14), and a footboard (16). The front end structure (12) forms the front portion of the vehicle (10). The rear end structure (14) forms the rear portion of the vehicle (10). The footboard (16) lies between the front end structure (12) and the rear end structure (14). The footboard (16) provides footrest for a rider riding the vehicle (10).

[0066] The front end structure (12) comprises a front ground engaging member (18), and a steering mechanism (20). The front ground engaging member (18) is operatively connected to the steering mechanism (20). In the illustrated example, the front ground engaging member (18) embodies a wheel. Alternatively, the front ground engaging member (18) embodies a track, without limiting the scope of the invention. The steering mechanism (20) comprises a handlebar (22). The handlebar (22) is configured to be rotated by the rider to steer the vehicle (10). Further, the front end structure (12) comprises a leg shield (24). The leg shield (24) encloses the steering mechanism (20). The leg shield (24) comprises an outer leg shield (26A) and an inner leg shield (26B). The leg shield (24) provides protection for the feet of the rider of the vehicle (10).

[0067] The front end structure (12) comprises a dash assembly (28). The dash assembly (28) comprises a display unit (not shown). The display unit displays information about the vehicle (10) to the rider. The dash assembly (28) may comprise additional components such as LCD, GPS, graphical user interface (GUI), etc. without limiting the scope of the invention. Further, the front end structure (12) may further comprise additional components such as mirror/s, head lamp/s, front fender/s, etc. without limiting the scope of the invention.

[0068] The rear end structure (14) comprises a seat (30), a rear ground engaging member (32), and a power unit (34). The seat (30) provides seating for a rider of the vehicle (10). The rear ground engaging member (32) underlies the seat (30) and is driven by the power unit (34). In the illustrated example, the power unit (34) is swingably coupled to a body frame structure (36). The power unit (34) comprises an engine (not shown) and a transmission unit (38). The transmission unit (38) is provided between the engine and the rear ground engaging member (32).

[0069] The rear end structure (14) comprises a storage box (not numbered). In the illustrated example, the storage box is provided under the seat (30). More particularly, the storage box is disposed within a space defined by the seat (30) and the engine of the power unit (34). In the illustrated example, the seat (30) is rotatably coupled to the storage box. In another example, the seat (30) may be rotatably coupled to the body frame structure (36). The seat (30) may be rotated manually, or with the assistance of a motor or an actuator or a solenoid, etc., without any limitations.

[0070] The body frame structure (36) supports the front end structure (12), the footboard (16), and the rear end structure (14). The body frame structure (36) comprises a head pipe (40) and a main frame (42) attached to the head pipe (40) so as to extend in a down-ward and rear-ward direction of the vehicle (10). The body frame structure (36) further comprises a first cross bar (44) attached to a free end of the main frame (42). By way of a non-limiting example, the free end of the main frame (42) is attached at about a centre of the first cross bar (44). The body frame structure (36) further comprises a right rear rail (46A) and left rear rail (46B) extending from the first cross bar (44) in a rear-ward and up-ward direction of the vehicle (10). By way of a non-limiting example, the right rear rail (46A) may be attached to a right end of the first cross bar (44) and the left rear rail (46B) may be attached to a left end of the first cross bar (44). A set of side covers (48) are mounted to the right rear rail (46A) and the left rear rail (46B). The head pipe (40) supports the steering mechanism (20). More particularly, the head pipe (40) pivotably supports the handlebar (22).

[0071] The vehicle (10) includes a front brake (50) associated with the front ground engaging member (18) and a rear brake (52) associated with the rear ground engaging member (32). In one embodiment, the front and the rear brakes (50, 52) can be disc brakes and/or drum brakes which can be actuated mechanically and/or electronically. The vehicle (10) further includes a fuel tank (54) disposed underneath the seat.

[0072] Now referring particularly to Figure 2, Figure 3, and Figure 4 there is illustrated a top view, a side view and a perspective view, respectively, of the body frame structure (36) without stay structure (100) attached thereto in accordance with an embodiment of the invention. The body frame structure (36) comprises a head pipe (40); a main frame (42) attached to the head pipe (40) so as to extend in a down-ward and rear-ward direction of the vehicle (10); a first cross bar (44) attached to a free end of the main frame (42); a right rear rail (46A) and left rear rail (46B) extending from the first cross bar (44) in a rear-ward and up-ward direction of the vehicle (10) ; and a stay structure (100) detachably attached to the right rear rail (46A) and the left rear rail (46B). In the present embodiment, the right rear rail (46A) comprises a first attachment part (56) for detachably attaching the stay structure (100) and the left rear rail (46B) comprises a second attachment part (58) for detachably attaching the stay structure (100). In an embodiment of the invention, the right rear rail (46A) comprises at least one first hanger part (60) for hanging the stay structure (100) and the left rear rail (46B) comprises at least one second hanger part (62) for hanging the stay structure (100). In the embodiment shown in Figure 2, Figure 3, and Figure 4, the stay structure (100) is attached to the right rear rail (46A) and the left rear rail (46B).

[0073] Now referring to Figure 5 and Figure 6, there is illustrated a top view and a perspective view, respectively, of a body frame structure (36) in accordance with an alternative embodiment and without the stay structure (100) attached thereto. In the alternative embodiment, the body frame structure (36) comprises a second cross plate (64) is attached between the right rear rail (46A) and the left rear rail (46B). In the present embodiment the second cross plate (64) comprises a third attachment part (66) and a fourth attachment part (68) for detachably attaching the stay structure (100). In an embodiment of the invention, the second cross plate (64) may additionally comprise a third hanger part (70) and a fourth hanger part (72) for hanging the stay structure (100). In the embodiment shown in Figure 5 and Figure 6, the stay structure (100) is attached to the second cross plate (64), which in turn is attached to the right rear rail (46A) and the left rear rail (46B).

[0074] Now referring to Figure 7 and Figure 8, there is illustrated a top view and a perspective view, respectively, of the body frame structure (36) in accordance with another alternative embodiment and without the stay structure (100) attached thereto. In the alternative embodiment, the body frame structure (36) comprises the second cross plate (64) and the third cross plate (74) attached between the right rear rail (46A) and the left rear rail (46B). In present embodiment, the second cross plate (64) comprises a third attachment part (66) and a fourth attachment part (68) for detachably attaching the stay structure (100). In an embodiment of the invention, the second cross plate (64) may additionally comprise a third hanger part (70) and a fourth hanger part (72) for hanging the stay structure (100). The third cross plate (74) may comprise attachment provisions for attachment to the fuel tank (54). In the embodiment shown in Figure 7 and Figure 8, the stay structure (100) is attached to the second cross plate (64), which in turn is attached to the right rear rail (46A) and the left rear rail (46B).

[0075] Referring to Figures 2 to 8, either or both of the right rear rail (46A) and the left rear rail (46B) may be provided with an attachment means (76) for attachment to the fuel tank (54).

[0076] Now referring to Figure 9 and Figure 10, there is illustrated a perspective view and a top view respectively, of the stay structure (100). The stay structure (100) co-operates with the right rear rail (46A) and the left rear rail (46B) for holding at least a fuel tank (54) and a rear fender (78) (best seen in Figure 11) of the vehicle (10). The stay structure (100) comprises a body portion (102) defining a first leg and a second leg (104, 106) spaced apart from each other. In an embodiment of the invention, the first leg (104) includes a first proximal portion (108) and a first distal portion (110). In an embodiment of the invention, the second leg (106) includes a second proximal portion (112) and a second distal portion (114). In an embodiment of the invention, the first distal portion (110) is connected to the second distal portion (114) such that the body portion is in the form a substantially V shape or a substantially U shape.

[0077] In an embodiment of the invention, the first proximal portion (108) comprises a first attachment part (116a) for attaching the stay structure (100) to the right rear rail (46A); and the second proximal portion (112) comprises a second attachment part (116b) for attaching the stay structure (100) to the left rear rail (46B). Thus, the stay structure (100) gets realisably attached to the right rear rail (46A) and the left rear rail (46B).

[0078] In an embodiment of the invention, the first attachment part (116a) comprises a first set of attachment means (120a) and the second attachment part (116b) comprises a second set of attachment means (120b), the first set of attachment means (120a) and the second set of attachment means (120b) being adapted to attach the stay structure (100) to the right rear rail (46A) and the left rear rail (46B), respectively.

[0079] In an embodiment of the invention, the first attachment part (116a) comprises a third set of attachment means (120c) and the second attachment part (116b) comprises a fourth set of attachment means (120d), the third set of attachment means (120c) and the fourth set of attachment means (120d) being adapted to attach the stay structure (100) to the fuel tank (54).

[0080] Thus, in an embodiment of the invention, the first set of attachment means (120a) and the third set of attachment means (120c) are formed in the first attachment part (116a). Likewise, in an embodiment of the invention, the second set of attachment means (120b) and the fourth set of attachment means (120d) are formed in the second attachment part (116b).

[0081] In an embodiment of the invention, the body portion (102) comprises a fifth set of attachment means (120e). The fifth set of attachment means (120e) can be used for attaching the stay structure (100) to the rear fender (78). By way of a non-limiting example, the fifth set of attachment means (120e) provides a multi-point attachment between the stay structure (100) and the rear fender (78).

[0082] Referring to Figure 11, there is illustrated a perspective view of the fuel tank (54) attached to the right rear rail (46A), the left rear rail (46B), the rear fender (78), and the stay structure (100). While in the prior art, the stay structure (100) forms part of the right rear rail (46A) and/or the left rear rail (46B), in the present invention, the stay structure (100) is detachable with respect to the right rear rail (46A) and the left rear rail (46B). As mentioned above, the stay structure (100) may be detachably attached to the right rear rail (46A) and the left rear rail (46B) or alternatively, the stay structure (100) may be detachably attached to the second cross plate (64), which in turn is attached to the right rear rail (46A) and the left rear rail (46B).

[0083] Since the stay structure (100) is detachable, it is substantially easy to assemble the fuel tank (54) on the vehicle (10) and more particularly between the rear fender (78), the right rear rail (46A), the left rear rail (46B) and the stay structure (100) substantially easily. Also, it is possible to easily dismantle the fuel tank (54) from the vehicle (10).

[0084] Now coming to the method of assembling the fuel tank (54) on the vehicle (10), said method comprises coupling the fuel tank (54) to a stay structure (100), a rear fender (78), a right rear rail (46A), and a left rear rail (46B) provided in a vehicle (10); wherein, at least two of the fuel tank (54), the rear fender (78), and the stay structure (100) are coupled to form a sub-assembly and the said sub-assembly is coupled to the right rear rail (46A) and the left rear rail (46B). In an embodiment of the invention, the sub-assembly can be any one of a first sub-assembly (122), a second sub-assembly (126), a third sub-assembly (128), or a fourth sub-assembly (130), details of which are provided in the following paragraphs.

[0085] Referring to Figures 12 to 16, the method of assembling comprises:
a. coupling the stay structure (100) and fuel tank (54) as shown in Figure 12 to obtain the first sub-assembly (122) as shown in Figure 13;
b. coupling the first sub-assembly (122) to the right rear rail (46A) and the left rear rail (46B) as shown in Figure 14 so as to obtain a first intermediate vehicle body part (124) as shown in Figure 15; and
c. coupling the rear fender (78) to the first intermediate vehicle body (124) as shown in Figure 16 to obtain the structure as shown in Figure 11.

[0086] In a preferred embodiment of the invention, initially the first sub-assembly (122) is attached to the attachment means (76) by aligning an oval shaped aperture present on the fuel tank (54) followed by fastening. After that, the first sub-assembly (122) is pulled back and hanged on the right rear rail (46A) and the left rear rail (46B) with help of the first hanger portion (118a) and the second hanger portion (118b) of the stay structure (100) by pushing the first sub-assembly (122) in a forward direction.

[0087] As a result of successful hanging of the first sub-assembly (122), there is no requirement of holding the first sub-assembly (122) by an operator while obtaining the first intermediate vehicle body part (124) followed by the structure as shown in Figure 11 with the help of fasteners for performing coupling. By a way of non-restrictive example the fasteners may be a nut and bolt combination.

[0088] Referring to Figure 17 to Figure 23, the method of assembling comprises:
a. coupling the stay structure (100) and fuel tank (54) as shown in Figure 12 to obtain the first sub-assembly (122) as shown in Figure 13;
b. coupling the first sub-assembly (122) to the rear fender (78) so as to obtain the second sub-assembly (126) as shown in Figure 18; and
c. coupling the second sub-assembly (126) to the right rear rail (46A) and the left rear rail (46B) as shown in Figure 19 to obtain the structure as shown in Figure 11.

[0089] In yet another embodiment of the invention, the method of assembling comprises:
a. coupling the stay structure (100) and rear fender (78) as shown in Figure 20 to obtain the third sub-assembly (128) as shown in Figure 21;
b. coupling the third sub-assembly (128) to the fuel tank (58) to obtain the second sub-assembly (126) as shown in Figure 18; and
c. coupling the second sub-assembly (126) to the right rear rail (46A) and the left rear rail (46B) as shown in Figure 19 to obtain the structure as shown in Figure 11.

[0090] In still another embodiment of the invention, the method of assembling comprises:
a. coupling the fuel tank (54) and the rear fender (78) as shown in Figure 22 to obtain the fourth sub-assembly (130) as shown in Figure 23;
b. coupling the fourth sub-assembly (130) to the stay structure (100) to obtain the second sub-assembly (126) as shown in Figure 18; and
c. coupling the second sub-assembly (126) to the right rear rail (46A) and the left rear rail (46B) as shown in Figure 19 to obtain the structure as shown in Figure 11.

[0091] In a further embodiment of the invention, the method of assembling comprises:
a. coupling the fuel tank (54) and the rear fender (78) as shown in Figure 22 to obtain the fourth sub-assembly (130) as shown in Figure 23;
b. coupling the fourth sub-assembly (130) to the right rear rail (46A) and the left rear rail (46B) to obtain a second intermediate vehicle body part; and
c. coupling the stay structure (100) to the second intermediate vehicle body part to obtain the structure as shown in Figure 11.

[0092] In a furthermore embodiment of the invention, the method of assembling comprises:
a. coupling the fuel tank (54), the rear fender (78) and the stay structure (100) as shown in Figure 17 to obtain the second sub-assembly (126) as shown in Figure 18 and;
b. coupling the second sub-assembly (126) to the right rear rail (46A) and the left rear rail (46B) as shown in Figure 19 to obtain the structure as shown in Figure 11.

[0093] In a preferred embodiment of the invention, initially the second sub-assembly (126) is attached to the attachment means (76) by aligning an oval shaped aperture (80) present on the fuel tank (54) followed by fastening. After that, the second sub-assembly (126) is pulled back and hanged on the on the right rear rail (46A) and the left rear rail (46B) with help of the first hanger portion (118a) and the second hanger portion (118b) of the stay structure (100) by pushing the second sub-assembly (126) in the forward direction.

[0094] As a result of successful hanging of the second sub-assembly (126), there is no requirement of holding the second sub-assembly (126) by the operator while obtaining the structure as shown in Figure 11 with the help of fasteners for performing coupling. By a way of non-restrictive example the fasteners may be a nut and bolt combination.

[0095] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0096] The figures and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.

[0097] Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. The scope of embodiments is at least as broad as given by the following claims.
, Claims:WE CLAIM:

1. A body frame structure (36) of a vehicle (10), comprising:
a head pipe (40);
a main frame (42) attached to the head pipe (40) so as to extend in a down-ward and rear-ward direction of the vehicle (10);
a first cross bar (44) attached to a free end of the main frame (42);
a right rear rail (46A) and left rear rail (46B) extending from the first cross bar (44) in a rear-ward and up-ward direction of the vehicle (10); and
a stay structure (100) detachably attached to the right rear rail (46A) and the left rear rail (46B).

2. The body structure as claimed in claim 1, wherein the right rear rail (46A) comprises a first attachment part (56) for detachably attaching the stay structure (100) and the left rear rail (46B) comprises a second attachment part (58) for detachably attaching the stay structure (100).

3. The body structure as claimed in claim 1, wherein the right rear rail (46A) comprises at least one first hanger part (60) for hanging the stay structure (100) and the left rear rail (46B) comprises at least one second hanger part (62) for hanging the stay structure (100).

4. The body structure as claimed in claim 1, wherein a second cross plate (64) is attached between the right rear rail (46A) and the left rear rail (46B).

5. The body structure as claimed in claim 4, wherein the second cross plate (64) comprises a third attachment part (66) and a fourth attachment part (68) for detachably attaching the stay structure (100).

6. The body structure as claimed in claim 4, wherein the second cross plate (64) comprises a third hanger part (70) and a fourth hanger part (72) for hanging the stay structure (100).

7. A stay structure (100) of a vehicle (10), the stay structure (100) co-operating with a right rear rail (46A), a left rear rail (46B) and for holding at least one of a fuel tank (54) and a rear fender (78) of the vehicle (10), said stay structure (100) comprising:
a body portion (102) defining a first leg and a second leg (104, 106) spaced apart from each other, the first leg (104) including a first proximal portion (108) and a first distal portion (110) and the second leg (106) including a second proximal portion (112) and a second distal portion (114), the first distal portion (110) being connected to the second distal portion (114) to form a substantially V or U shape;
the first proximal portion (108) comprising a first attachment part (116a) for attaching the stay structure (100) to the right rear rail (46A); and
the second proximal portion (112) comprising a second attachment part (116b) for attaching the stay structure (100) to the left rear rail (46B).

8. The stay structure as claimed in claim 7, wherein the first attachment part (116a) comprises a first set of attachment means (120a) and the second attachment part (116b) comprises a second set of attachment means (120b), the first set of attachment means (120a) and the second set of attachment means (120b) being adapted to attach the stay structure (100) to the right rear rail (46A) and the left rear rail (46B), respectively.

9. The stay structure as claimed in claim 7, wherein the first attachment part (116a) comprises a third set of attachment means (120c) and the second attachment part (116b) comprises a fourth set of attachment means (120d), the third set of attachment means (120c) and the fourth set of attachment means (120d) being adapted to attach the stay structure (100) to the fuel tank (54).

10. The stay structure as claimed in claim 7, wherein the body portion (102) comprises a fifth set of attachment means (120e) for attaching the stay structure (100) to the rear fender (78).

11. The stay structure as claimed in claim 7, wherein the first attachment part (116a) comprises a first hanger portion (118a) for hanging the stay structure (100) to the right rear rail (46A) rear frame (206) and the second attachment part (116b) comprises a second hanger portion (118b) for hanging the stay structure (100) to the left rear rail (46B).

12. A vehicle (10), comprising:
A power unit (34);
a front ground engaging member (18) and a rear ground engaging member (32) deriving power from the power unit (34);
a fuel tank (54) coupled to a body frame structure (36) of the vehicle (10); the body frame structure (36) comprising:
a head pipe (40);
a main frame (42) attached to the head pipe (40) so as to extend in a down-ward and rear-ward direction of the vehicle (10);
a first cross bar (44) attached to a free end of the main frame (42);
a right rear rail (46A) and left rear rail (46B) extending from the first cross bar (44) in a rear-ward and up-ward direction of the vehicle (10); and
a stay structure (100) detachably attached to the right rear rail (46A) and the left rear rail (46B).

13. A method of assembling a fuel tank (54) to a vehicle (10), said method comprising:
coupling the fuel tank (54) to a stay structure (100), a rear fender (78), a right rear rail (46(A), and a left rear rail (46B);
wherein, at least two of the fuel tank (54), the rear fender (78), and the stay structure (100) are coupled to form a sub-assembly and the said sub-assembly is coupled to the right rear rail (46(A), and the left rear rail (46B).

14. The method as claimed in claim 13, wherein the sub-assembly is any one of a first sub-assembly (122), a second sub-assembly (126), a third sub-assembly (128), or a fourth sub-assembly (130).

15. The method as claimed in claim 14, wherein the method of assembling comprises:
a. coupling the stay structure (100) and fuel tank (54) to obtain the first sub-assembly (122);
b. coupling the first sub-assembly to the right rear rail (46A) and the left rear rail (46B) so as to obtain a first intermediate vehicle body part (124); and
c. coupling the rear fender (78) the first intermediate vehicle body part (124).

16. The method as claimed in claim 14, wherein the method of assembling comprises:
a. coupling the stay structure (100) and fuel tank (54) to obtain the first sub-assembly (122);
b. coupling the first sub-assembly (122) to the rear fender (78) to obtain the second sub-assembly (126); and
c. coupling the second sub-assembly (126) to the right rear rail (46A) and the left rear rail (46B).

17. The method as claimed in claim 14, wherein the method of assembling comprises:
a. coupling the stay structure (100) and rear fender (78) to obtain the third sub-assembly (128);
b. coupling the third sub-assembly (128) to the fuel tank (54) to obtain the second sub-assembly (126); and
c. coupling the second sub-assembly (126) to the right rear rail (46A) and the left rear rail (46B).

18. The method as claimed in claim 14, wherein the method of assembling comprises:
a. coupling the fuel tank (54) and the rear fender (78) to obtain the fourth sub-assembly (130);
b. coupling the fourth sub-assembly (130) to the stay structure (100) to obtain the second sub-assembly (126); and
c. coupling the second sub-assembly (126) to the right rear rail (46A) and the left rear rail (46B).

19. The method as claimed in claim 14, wherein the method of assembling comprises:
a. coupling the fuel tank (54) and the rear fender (78) to obtain the fourth sub-assembly (130);
b. coupling the fourth sub-assembly (130) to the right rear rail (46A) and the left rear rail (46B) to obtain a second intermediate vehicle body part; and
c. coupling the stay structure (100) to the second intermediate vehicle body part.

20. The method as claimed in claim 14, wherein the method of assembling comprises:
a. coupling the fuel tank (54), the rear fender (78) and the stay structure (100) to obtain the second sub-assembly (126); and
b. coupling the second sub-assembly (126) to the right rear rail (46A) and the left rear rail (46B).

21. The method as claimed in claim 14, wherein the method of assembling comprises:
a. coupling the first sub-assembly (122) to the body frame structure (36) by fastening an oval shaped aperture (80) of the fuel tank (54) with the attachment means (76); and
b. coupling the first sub-assembly (122) to the right rear rail (46A) and the left rear rail (46B) of the stay structure (100) by pulling the first sub-assembly (122) in rear direction of the vehicle (10) and followed by pushing the first sub-assembly (122) in a forward direction of the vehicle (10) that enables the first sub-assembly (122) to remain in hanged state for completion of further assembling without need of any operator.