DESC:FIELD OF DISCLOSURE
The present disclosure relates to vehicles. Particularly, the present disclosure relates to a kick-start assembly for kick starting a two-wheeler.
DEFINITIONS
The expressions “crankcase LH” and “crankcase RH” referred herein in this disclosure refers to left hand side and right hand side respectively of a crankcase utilized to house a crankcase assembly.
This definition is in addition to those expressed in the art.
BACKGROUND
In two-wheeled vehicles, kick-start assemblies are used to start the internal combustion engines by co-operating with a power transmission system. Kick-start assemblies include a kick pedal coupled to a kick shaft such that the operation of the kick pedal facilitates rotation of the kick shaft. In response to the rotation of the kick shaft, a crankshaft is operated by a drive train, which in turn starts the internal combustion engine.
The conventional kick-start assembly includes a conventional kick shaft return spring, generally a double coil torsion spring or double helical coil spring, which is engaged with the kick shaft at one end and is engaged with a stopper bolt screwed with a threaded hole of the crankcase at the other end. In order to accommodate the conventional kick shaft return spring i.e. double coil torsion spring, a relatively larger space is required. Hence, in conventional vehicles, the center distance between the kick shaft and the output shaft is comparatively more for accommodating the double coil torsion spring, thereby increasing the size of a transmission assembly of the two-wheeled vehicle that in turn increases the cost. Further, the manufacturing of the double coil spring is a tedious process, which results in increased manufacturing cost.
Alternatively, the conventional kick-start assemblies require a continuously variable transmission (CVT) for transferring power from the shaft of the kick pedal to the transmission output shaft of the engine, thereby reducing torque transmission capability of the transmission assembly of the two-wheeled vehicle due to limited torque handling capacity of the CVT. Also, the CVT are not cost effective and are prone to early wear out.
Further, the conventional kick-start assemblies require additional members or elements for securing the kick shaft return spring, which makes conventional assemblies heavy and bulky.
Hence, there is a need to alleviate some drawbacks associated with conventional kick-start assemblies.

OBJECTS
Some of the objects of the kick-start assembly of the present disclosure are aimed to ameliorate one or more problems of the prior art or to at least provide a useful alternative and are listed herein below.
An object of the present disclosure is to provide an efficient kick-start assembly.
Another object of the present disclosure is to provide a compact kick-start assembly.
Yet another object of the present disclosure is to provide a kick-start assembly with comparatively reduced components.
Still another object of the present disclosure is to provide a cost effective kick-start assembly.
Another object of the present disclosure is to provide a kick-start assembly that is light in weight.
Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.

SUMMARY
A kick-start assembly for kick starting a two-wheeler by driving the crankshaft is disclosed, the kick-start assembly comprising:
? a kick pedal;
? a kick shaft connected between the kick pedal and the crankshaft; and
? a single helical coil spring connected co-axially to the kick shaft defining a first end and a second end, the first end connected to the kick shaft and the second end connected to a protrusion configured on inner side the crankcase body to spring load the kick shaft and therefore the kick pedal in an operative configuration of the kick-start assembly.
More specifically, the kick-start assembly includes a crankcase, a crank cover, a kick shaft, a kick pedal, a ratchet and dog clutching mechanism, an output shaft, an input shaft, a crankshaft and a single helical coil spring. The crankcase includes a crankcase LH and a crankcase RH. The crankcase LH has a protrusion and an angular cavity configured thereon. The crankcase RH is coupled with the crankcase LH. The crank cover is removably coupled with the crankcase RH to form an enclosed space therein. The kick shaft is received and supported by the crankcase and the crank cover. The kick shaft has a first end portion and a second end portion. The first end portion is supported by the protrusion and the second end portion outwardly extends from the crank cover. The kick pedal is connected to the second end portion of the kick shaft. Further, the kick shaft has a kick gear disposed thereon. The kick pedal is moved from original position for enabling the angular displacement of the kick shaft. The ratchet and dog clutching mechanism is co-axially disposed on the kick shaft and adjacent to the kick gear. The ratchet and dog mechanism is axially displaced on the kick shaft by a spring. The spring is actuated by the kick pedal, wherein in an operative configuration the ratchet and dog clutching mechanism forwardly moves and engages with the kick gear for enabling the rotation of the kick gear and in an inoperative configuration the ratchet and dog clutching mechanism backwardly moves and disengages with the kick gear for freewheeling the kick gear on the kick shaft. The output shaft is spaced from and parallel to the kick shaft. The output shaft has a first driven gear disposed thereon meshing with the kick gear for enabling the rotation of the output shaft. The input shaft is spaced from and parallel to the output shaft. The input shaft has a first drive gear and a primary driven gear. The first drive gear is disposed thereon meshing with the first driven gear for enabling the rotation of the input shaft. The primary driven gear is adjacently disposed to the first drive gear. The crankshaft is spaced from and parallel to the input shaft. The crankshaft has a primary drive gear disposed thereon meshing with the primary driven gear for enabling the rotation of the crankshaft that in turn actuates the internal combustion engine.
In accordance with the present disclosure, the single helical coil spring has:
a first end that is free and disposed on the kick shaft; and
a second end that is bent and disposed on the protrusion with an edge thereof securely engaged within the angular cavity.
In accordance with the present disclosure, the single helical coil spring enables the kick pedal to return to the original position during the backwardly movement of the ratchet and dog clutching mechanism.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
The kick-start assembly of the present disclosure will now be described with the help of the accompanying drawings, in which:
Figure 1 illustrates a cut section view of a kick-start assembly co-operating with a power transmission system of a vehicle in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a closer cut section view of the kick-start assembly co-operating with a power transmission system of Figure 1;
Figure 3 illustrates a perspective view of a guiding means used for a kick shaft and a mounting arrangement of a single helical coil spring of the kick-start assembly of Figure 1;
Figure 4 illustrates a front view of the guiding means used for the kick shaft and the mounting arrangement of the single helical coil spring of the kick-start assembly of Figure 1;
Figure 5 illustrates a front view of the mounting arrangement of the single helical coil spring of the kick-start assembly of Figure 1;
Figure 6 illustrates a perspective view of an arrangement of a ratchet stopper plate and a ratchet guide plate of the kick-start assembly of Figure 1; and
Figure 7 illustrates a front view of the arrangement of the ratchet stopper plate and the ratchet guide plate along with the mounting bolts of the kick-start assembly of Figure 1.
DETAILED DESCRIPTION
The kick-start assembly of the present disclosure will now be described with reference to the embodiments of the present disclosure. The embodiments do not limit the scope and ambit of the disclosure. The description relates purely to the examples and preferred embodiments of the disclosed kick-start assembly and its suggested applications and/or use.
The arrangement herein, the various features, and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known parameters and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
Various embodiments of the present disclosure will now be explained with reference to Figure 1 through Figure 7 wherein the key components are referenced generally by numerals as indicated in the accompanying drawings.
In accordance with an embodiment of the present disclosure, a kick-start assembly for kick starting a two-wheeler by driving the crankshaft is disclosed, the kick-start assembly comprising:
? a kick pedal;
? a kick shaft connected between the kick pedal and the crankshaft; and
? a single helical coil spring connected co-axially to the kick shaft defining a first end and a second end, the first end connected to the kick shaft and the second end connected to a protrusion configured on inner side the crankcase body to spring load the kick shaft and therefore the kick pedal in an operative configuration of the kick-start assembly.
More specifically, Figure 1 illustrates a cut section view of a kick-start assembly 100 co-operating with a power transmission system of a vehicle in accordance with an embodiment of the present disclosure. The kick-start assembly 100 is used for actuating an internal combustion system of the vehicle. The kick-start assembly 100 of the present disclosure includes:
? a crankcase comprising a left hand portion of the crankcase LH 214 and a right hand portion of the crankcase RH 216;
? a crank cover 208 removably coupled with the crankcase to form an enclosed space therein;
? a kick shaft 104;
? a kick pedal 102;
? a ratchet and dog clutching mechanism (not indicated);
? an output shaft 114;
? an input shaft 116;
? a crankshaft 120; and
? a single helical coil spring 106.
In accordance with the present disclosure, the kick shaft 104 has a first end portion 104a and a second end portion 104b and is received and supported by the crankcase (214, 216) and the crank cover 208. Typically, the kick shaft 104 is angularly displaced by the kick pedal 102, which is mounted on the second end portion 104b of the kick shaft 104 typically on the outer side of the crank cover 208. A kick gear 108 is disposed on the kick shaft 104 that is rotatable by the operation of the kick pedal 102. The kick gear 108 is engaged with a first driven gear 110, which is mounted on the output shaft 114 at one end. The first driven gear 110 engages with a first drive gear 112, which is mounted on the input shaft 116. Power is transferred from the kick shaft 104 to the input shaft 116 and further from the input shaft 116 to the crankshaft 120 with the help of an engagement of a primary driven gear 118 and a primary drive gear 122.
More specifically, the output shaft 114 is spaced from and is parallel to the kick shaft 104. The first driven gear 110 disposed on the output shaft 114 meshes with the kick gear 108. Further, the input shaft 116 is spaced from and is parallel to the output shaft 114. The first drive gear 112 disposed the input shaft 116 meshes with the first driven gear 110. The input shaft 116 also has the primary driven gear 118 adjacently disposed to the first drive gear 112. Still further, the crankshaft 120 is spaced from and parallel to the input shaft 116. The primary drive gear 122 disposed on the crankshaft 120 meshes with the primary driven gear 118 for enabling the rotation of the crankshaft 120 for actuating the internal combustion engine.
Figure 2 illustrates a closer cut section view of the kick-start assembly 100 co-operating with a power transmission system of Figure 1. The ratchet and dog clutching mechanism is functionally connected to the kick shaft 104. The ratchet and dog clutching mechanism include a first ratchet 204a, a first dog 206a, a second ratchet 204b and a second dog 206b. The first ratchet 204a is disposed on the kick shaft 104 in the vicinity of the kick gear 108. The first ratchet 204a is connected to a spring 202, typically a helical spring. The helical spring 202 is connected to a thrust washer 212. In an operative configuration, the angular displacement of the kick shaft 104 causes the helical spring 202 to extend axially that in turn forwardly moves the first ratchet 204a. The first ratchet 204a is coupled with the first dog 206a. The forward movement of the first ratchet 204a forwardly moves the first dog 206a to get coupled with the second dog 206b which is coupled with the second ratchet 204b. The second ratchet 204b is functionally coupled with the kick gear 108. As soon as the first dog 206a is coupled with the second dog 206b and thereby with the second ratchet 204b, the kick gear 108 starts rotating. In an inoperative configuration, the first ratchet 204a backwardly moves. This backward movement of the first ratchet 204a disengages the connection between the first dog 206a and the second dog 206b and thereby the second ratchet 204b. As soon as the first dog 206a is disengaged with the second dog 206b and thereby the second ratchet 204b, the kick gear 108 gets freewheeled on the kick shaft 104.
In accordance with one embodiment of the present disclosure, a spring guide 210, typically of plastic material, is disposed between the single helical coil spring 106 and the kick shaft 104.
Figure 3 illustrates a perspective view of a guiding means used for a kick shaft and a mounting arrangement of a single helical coil spring of the kick-start assembly 100 of Figure 1. More specifically, Figure 3 illustrates a protrusion 302 and an angular cavity 306 for securing single helical coil spring 106 configured on the inner side of the crankcase LH 214 (or the crankcase body). In one embodiment, the protrusion 302 and the angular cavity 306 are integrally formed on the crankcase LH 214. Typically, the first end portion 104a of the kick shaft 104 is supported by the protrusion 302 and the second end portion 104b outwardly extends from the crank cover 208 (as shown in Figure 1 and Figure 2). Further, the crankcase RH 216 is coupled with the crankcase LH 214.
In accordance with the present disclosure, the inner side of the crankcase LH 214 features a circular protuberance 308 configured thereon.
In accordance with the present disclosure, the angular cavity 306 and the protrusion 302 provided on the crankcase LH 214 is used to secure the single helical coil spring 106, thereby eliminating the requirement of additional member or element for securing the single helical coil spring 106, such as a stopper and a shoulder bolt used by the kick-start assemblies of the prior art. Thus, the assembly of the kick-start assembly of the present disclosure is light in weight with reduced structural complexity. In addition, the single helical coil spring 106 is small in size as compared with conventional double-coiled torsion spring and hence requires comparatively less space in the power transmission system. More specifically, the use of the single helical coil spring 106 requires comparatively less distance between the kick shaft 104 and the output shaft 114 as compared to conventional double coil torsion spring that requires comparatively more distance between the kick shaft and the output shaft. Hence, the use of the single helical coil spring makes the power transmission system compact.
Figure 4 illustrates a front view of the guiding means used for the kick shaft and the mounting arrangement of the single helical coil spring 106 of the kick-start assembly 100 of Figure 1. The single helical coil spring 106 includes a first end 403 that is free and a second end 402 that is bent. The free first end 403 is disposed around the kick shaft 104. Typically, the free first end 403 of the kick return single helical coil spring 106 is disposed within a slot 104c configured on a portion of the kick shaft 104 and the second end 402 that is bent is engaged into the crankcase LH 214 provided with the protrusion 302 acting as a stopper. The protrusion 302 prevents the single helical coil spring 106 from falling off from the slot 104c. An edge 402a of the second end 402 is disposed in the angular cavity 306 of the crankcase LH 214. The second end 402 is bent at a pre-determined angle in order to extend towards the crankshaft 120 and parallel to the kick shaft 104.
In an operative configuration the single helical coil spring 106 is connected co-axially to said kick shaft defining the first end 403 and a second end 402, said first end 403 is connected to said kick shaft 104 and said second end 402 is connected to the protrusion 302 configured on inner side the crankcase body to spring load said kick shaft 104 and therefore said kick pedal 102 in an operative configuration of the kick-start assembly 100.
Figure 5 illustrates a front view of the mounting arrangement of the single helical coil spring of the kick-start assembly of Figure 1;
Figure 6 illustrates a perspective view of an arrangement of a ratchet stopper plate and a ratchet guide plate of the kick-start assembly of Figure 1; and
Figure 7 illustrates a front view of the arrangement of the ratchet stopper plate 602 and the ratchet guide plate 604 along with the mounting bolts of the kick-start assembly of Figure 1. Referring to Figure 6 and Figure 7, the ratchet stopper plate 602 and a ratchet guide plate 604 is provided for preventing motion of the first ratchet 204a and the second ratchet 204b in a radial direction and an axial direction respectively after starting of the engine. At least one ratchet stopper bolt 606 is provided for clamping the ratchet stopper plate 602 and the ratchet guide plate 604 with the crankcase LH 214. The ratchet stopper plate 602 and the ratchet guide plate 604 are bolted on the circular protuberance 308 of the crankcase LH 214.
Thus, the kick-start assembly 100 of the present disclosure utilizes the single helical coil spring 106 that firmly engages with the crankcase without requiring any additional fastening means and securing means, thereby requiring less inner space of the crankcase that makes the arrangement compact in structure with reduced components.
Further, the single helical coil spring 106 is easy to manufacture, thus resulting in lower manufacturing cost.
Still further, the protrusion 302 created in the crankcase LH 214 for guiding and supporting the kick shaft 104 is such that the bending of the kick shaft 104 is reduced.
A method of starting the internal combustion engine by the kick-start assembly 100 is disclosed. Initially, the kick pedal 102 is angularly displaced by moving it from its original position. The angular displacement of the kick pedal rotates the kick shaft 104 and actuates the ratchet and dog clamping mechanism. More specifically, the rotation of the kick pedal 102 and the kick shaft 104 actuates the helical spring 202 that pushes the first ratchet 204a with the first dog 206a in forward direction till the first dog 206a is coupled with the second dog 206b and thereby the second ratchet 204b connected to the kick gear 108. In addition, as the kick shaft 104 is rotated, the ratchet and dog clamping mechanism disposed thereon rotates thereby causing rotation of the kick gear 108. As the kick gear 108 rotates, the first driven gear 110 rotates thereby rotating the output shaft 114. Further, the rotation of the first driven gear 110 rotates the first drive gear 112 thereby rotating the input shaft 116. The rotation of the input shaft 116 rotates the primary driven gear 118 mounted thereon. The primary driven gear 118 in turn rotates the primary drive gear 122 mounted on the crankshaft 120 thereby rotating the crankshaft 120. The rotation of the crankshaft 120 actuates the internal combustion engine.
As soon as the internal combustion engine is actuated, the ratchet and dog clamping mechanism gets de-actuated. More specifically, the first ratchet 204a moves in backward direction along with the first dog 206a. This backward movement disengages connection between the first dog 206a and the second dog 206b that causes freewheeling of the kick gear 108. Simultaneously, the single helical coil spring 106 gets actuated for actuating the kick pedal 102 to return to its original position.
Although the mechanism of the present disclosure is described with reference to the aforementioned embodiments, other configurations of the system are included in the scope of the present disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
The technical advancements offered by the present disclosure include the realization of a kick-start assembly that:
? is efficient;
? is compact;
? is easily operable;
? has reduced number of components;
? is cost effective;
? is light in weight; and
? is characterized by a smooth operation.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The foregoing description of the specific embodiment will so fully reveal the general nature of the embodiment herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiment without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiment. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiment herein has been described in terms of preferred embodiment, those skilled in the art will recognize that the embodiment herein can be practiced with modification within the spirit and scope of the embodiment as described herein.
,CLAIMS:1. A kick-start assembly for kick starting a two-wheeler by driving the crankshaft, said kick start assembly comprising:
? a kick pedal;
? a kick shaft connected between said kick pedal and the crankshaft; and
? a single helical coil spring connected co-axially to said kick shaft defining a first end and a second end, said first end connected to said kick shaft and said second end connected to a protrusion configured on inner side the crankcase body to spring load said kick shaft and therefore said kick pedal in an operative configuration of the kick-start assembly.
2. The kick-start assembly as claimed in claim 1, wherein a first end portion of said kick shaft is rotatably received in said protrusion configured on the inner side of said crankcase body and a second end portion of said kick shaft extends out from said crankcase body.
3. The kick-start assembly as claimed in claim 1, wherein said first end of said single helical coil spring is received by a slot formed on said kick shaft.
4. The kick-start assembly as claimed in claim 1, wherein said second end of said single helical coil spring is bent and is disposed on said protrusion with an edge thereof securely engaged within an angular cavity configured on said inner side of the crankcase body.
5. The kick-start assembly as claimed in claim 1, wherein said kick-start assembly comprises:
? a kick gear disposed on said kick shaft;
? a ratchet and dog clutching mechanism is co-axially and displaceably disposed on said kick shaft adjacent to said kick gear, said ratchet and dog clutching mechanism adapted to be axially displaced on said kick shaft by a spring, wherein
o said ratchet and dog clutching mechanism, in an operative configuration, axially moves in an operative forward direction and engages with said kick gear for enabling rotation of said kick gear; and
o said ratchet and dog clutching mechanism, in an inoperative configuration, moves in an operative backward direction and disengages with said kick gear for freewheeling said kick gear on said kick shaft;
? an output shaft spaced from and parallel to said kick shaft, said output shaft having a first driven gear disposed thereon meshing with said kick gear for enabling rotation of said output shaft;
? an input shaft spaced from and parallel to said output shaft, said input shaft having:
o a first drive gear disposed thereon meshing with said first driven gear for enabling rotation of said input shaft; and
o a primary driven gear adjacently disposed to said first drive gear; and
? a primary drive gear disposed said crankshaft meshing with said primary driven gear for enabling rotation of said crankshaft that in turn actuates the internal combustion engine, wherein said single helical coil spring enables said kick pedal to return to said original position during the backwardly movement of said ratchet and dog clutching mechanism.
6. The kick-start assembly as claimed in claim 1, wherein a spring guide is disposed between said kick shaft and said single helical coil spring.
7. The kick-start assembly as claimed in claim 1, wherein a thrust washer is functionally coupled to said spring.
8. The kick-start assembly as claimed in claim 5, wherein a ratchet stopper plate is disposed on inner side of said crankcase body to prevent radial movement of ratchets of said ratchet and dog clutching mechanism, said ratchet stopper plate is clamped with said crankcase body by bolts.
9. The kick-start assembly as claimed in claim 5, wherein a ratchet guide plate disposed on said crankcase body to prevent axial movement of said ratchets of said ratchet and dog clutching mechanism, said ratchet guide plate is clamped to said crankcase body by bolts.