Claims:WE CLAIM:
1. A kick starter assembly (100) for a vehicle (200), the assembly (100) comprising:
a lever (102) coupled onto a starter shaft (104) disposed in a cover variator (202) of the vehicle (200), the lever (102) operable to an engaged position from an idle position for rotating the starter shaft (104);
a gear mechanism (106) adapted to transfer rotational movement of the starter shaft (104) to a crankshaft (204) of an internal combustion engine (208) of the vehicle (200), the gear mechanism (106) comprising:
a drive gear (108) mounted onto the starter shaft (104);
a driven gear (110) mounted onto the crankshaft (204) and axially movable thereon, the driven gear (110) comprising a helical gear (110a) coupled to the drive gear (108) for receiving the rotational movement and a helical ratchet (110b) adapted to selectively engage with a crankshaft ratchet (206) for transferring the rotational movement to the crankshaft (204);
a retainer spring (112) mounted onto the driven gear (110) and adapted to selectively allow axial displacement of the driven gear (110) on the crankshaft (204) for engagement with the crankshaft ratchet (206); and
a stopper member (114) mounted onto the drive gear (108) and adapted to selectively engage and disengage with the retainer spring (112) corresponding to rotation of the drive gear (108),
wherein, the stopper member (114) is adapted to secure the retainer spring (112) upon engagement, to inhibit axial displacement of the driven gear (110), and
wherein, the retainer spring (112) urges axial displacement of the driven gear (110) for coupling with the crankshaft ratchet (206) upon disengagement with the stopper member (114), to transfer rotational movement to the crankshaft (204) for kick-starting the vehicle (200).

2. The assembly (100) as claimed in claim 1, wherein the retainer spring (112) comprises a collar region (116) extending towards the drive gear (108), the collar region (116) including a fore end (116a) supported on a wall (202a) of the cover variator (202) and an aft end (116b) of the collar region (116) adapted to engage with the stopper member (114).

3. The assembly (100) as claimed in claim 2, wherein the stopper member (114) is mounted on the drive gear (108) at a location substantially above the aft end (116b) of the collar region (116) of the retainer spring (112) for engagement therewith.

4. The assembly (100) as claimed in claim 1, wherein the stopper member (114) engages with the retainer spring (112) in idle position of the lever (102).

5. The assembly (100) as claimed in claim 1, wherein the stopper member (114) disengages from the retainer spring (112) in engaged position of the lever (102).

6. The assembly (100) as claimed in claim 1, wherein the stopper member (114) is made of rubber material.

7. The assembly (100) as claimed in claim 1, wherein the vehicle (200) is a two-wheeled vehicle.

8. A two-wheeled vehicle (200), comprising:
an internal combustion engine (208) mounted on frame member of the vehicle (200); and
a kick starter assembly (100) coupled to the internal combustion engine (208), the assembly (100) comprising:
a lever (102) coupled onto a starter shaft (104) disposed in a cover variator (202) of the vehicle (200), the lever (102) operable to an engaged position from an idle position for rotating the starter shaft (104);
a gear mechanism (106) adapted to transfer rotational movement of the starter shaft (104) to a crankshaft (204) of the internal combustion engine (208) of the vehicle (200), the gear mechanism (106) comprising:
a drive gear (108) mounted onto the starter shaft (104);
a driven gear (110) mounted onto the crankshaft (204) and axially movable thereon, the driven gear (110) comprising a helical gear (110a) coupled to the drive gear (108) for receiving the rotational movement and a helical ratchet (110b) adapted to selectively engage with a crankshaft ratchet (206) for transferring the rotational movement to the crankshaft (204);
a retainer spring (112) mounted onto the driven gear (110) and adapted to selectively allow axial displacement of the driven gear (110) on the crankshaft (204) for engagement with the crankshaft ratchet (206); and
a stopper member (114) mounted onto the drive gear (108) and adapted to selectively engage and disengage with the retainer spring (112) corresponding to rotation of the drive gear (108),
wherein, the stopper member (114) is adapted to secure the retainer spring (112) upon engagement, to inhibit axial displacement of the driven gear (110), and
wherein, the retainer spring (112) urges axial displacement of the driven gear (110) for coupling with the crankshaft ratchet (206) upon disengagement with the stopper member (114), to transfer of rotational movement to the crankshaft (204) for kick-starting the vehicle (200).

9. The vehicle (200) as claimed in claim 8, wherein the retainer spring (112) comprises a collar region (116) extending towards the drive gear (108), the collar region (116) including a fore end (116a) supported on a wall (202a) of the cover variator (202) and an aft end (116b) of the collar region (116) are adapted to engage with the stopper member (114).

10. The vehicle (200) as claimed in claim 9, wherein the stopper member (114) is mounted on the drive gear (108) at a location substantially above the aft end (116b) of the collar region (116) of the retainer spring (112) for engagement therewith.

11. A method of assembling a kick starter assembly 100 of a vehicle, comprising:
coupling, a lever (102) onto a starter shaft (104) disposed in a cover variator (202) of the vehicle (200), the lever (102) operable to an engaged position from an idle position for rotating the starter shaft (104);
mounting, a drive gear (108) onto the starter shaft (104);
mounting, a driven gear (110) onto the crankshaft (204) and axially movable thereon, wherein the driven gear (110) comprises a helical gear (110a) coupled to the drive gear (108) for receiving the rotational movement and a helical ratchet (110b) adapted to selectively engage with a crankshaft ratchet (206) for transferring the rotational movement to the crankshaft (204);
mounting a retainer spring (112) onto the driven gear (110) and adapted to selectively allow axial displacement of the driven gear (110) on the crankshaft (204) for engagement with the crankshaft ratchet (206); and
mounting a stopper member (114) onto the drive gear (108) to selectively engage and disengage with the retainer spring (112) corresponding to rotation of the drive gear (108),
wherein, the stopper member (114) is adapted to secure the retainer spring (112) upon engagement, to inhibit axial displacement of the driven gear (110), and
wherein, the retainer spring (112) urges axial displacement of the driven gear (110) for coupling with the crankshaft ratchet (206) upon disengagement with the stopper member (114), to transfer of rotational movement to the crankshaft (204) for kick-starting the vehicle (200).

12. The method as claimed in claim 11, wherein the retainer spring (112) comprises a collar region (116) including a fore end (116a) supported on a wall (202a) of the cover variator (202) and an aft end (116b) of the collar region (116) are adapted to engage with the stopper member (114).

13. The method as claimed in claim 12, wherein the stopper member (114) is mounted on the drive gear (108) at a location substantially above the aft end (116b) of the collar region (116) of the retainer spring (112) for engagement therewith.
, Description:FIELD OF THE INVENTION
[001] The present invention relates to starter assembly for a vehicle, particularly a kick starter assembly for the vehicle.

BACKGROUND OF THE INVENTION
[002] Vehicles, such as two-wheeled vehicles, are provided with a kick starter assembly for reliable starting of an engine. Typically, the kick starter assembly includes a gear pair having a drive gear connected to a kick shaft and a helical driven gear-ratchet which moves axially to engage with a crankshaft ratchet. A user upon applying torque onto the kick shaft, drives the gear pair suitably for cranking of the engine, consequently starting the engine.
[003] However, due to vibration or leaning during vehicle movement, the helical driven gear-ratchet in the conventional kick starter assembly moves out axially to engage with the crankshaft ratchet, without the requirement of rotation from the drive gear. Such an engagement with the crankshaft shaft, while the engine is running, results in backlash between the drive gear and an idling driven gear that connects the drive gear to the helical drive gear-ratchet. The backlash consequently results in generation of noise, which is undesirable.
[004] To overcome the aforementioned limitations, the kick starter assembly is provided with rubber dampers between faces of the meshing gears to dampen the noise generated. However, use of rubber damper in a dusty, humid environment where the chances of exposure to water and dust are high, causes the rubber damper to wear-out, thereby requiring constant replacement and servicing. Moreover, the rubber damper also generates heat due to friction caused during rubbing between the meshing gears, which also leads to wearing out of the rubber damper.
[005] In view of the above, there is a need for a kick starter assembly, which addresses one or more limitations stated above.

SUMMARY OF THE INVENTION
[006] In one aspect, a kick starter assembly for a vehicle is disclosed. The assembly includes a lever coupled onto a starter shaft disposed in a cover variator of the vehicle, the lever being operable to an engaged position from an idle position for rotating the starter shaft. A gear mechanism is adapted to transfer rotational movement of the starter shaft to a crankshaft of an internal combustion engine of the vehicle. The gear mechanism includes a drive gear mounted onto the starter shaft and a driven gear mounted onto the crankshaft and axially movable thereon. The driven gear includes a helical gear coupled to the drive gear for receiving the rotational movement and a helical ratchet adapted to selectively engage with a crankshaft ratchet for transferring the rotational movement to the crankshaft. A retainer spring is mounted onto the driven gear and is adapted to selectively allow axial displacement of the driven gear on the crankshaft for engagement with the crankshaft ratchet. A stopper member is mounted onto the drive gear and is adapted to selectively engage and disengage with the retainer spring corresponding to rotation of the drive gear. The stopper member is adapted to secure the retainer spring upon engagement, to inhibit axial displacement of the driven gear. While, the retainer spring urges axial displacement of the driven gear for coupling with the crankshaft ratchet upon disengagement with the stopper member, to transfer of rotational movement to the crankshaft for kick-starting the vehicle.
[007] In an embodiment, the retainer spring includes a collar region extending towards the drive gear. The collar region includes a fore end supported on a wall of the cover variator and an aft end of the collar region are adapted to engage with the stopper member.
[008] In an embodiment, the stopper member is mounted on the drive gear at a location substantially above the aft end of the collar region of the retainer spring for engagement therewith.
[009] In an embodiment, the stopper member engages with the retainer spring in idle position of the lever.
[010] In an embodiment, the stopper member disengages from the retainer spring in engaged position of the lever.
[011] In an embodiment, the stopper member is made of rubber material.
[012] In another aspect, a two-wheeled vehicle is disclosed. The vehicle includes an internal combustion engine mounted on a frame member of the vehicle and the kick starter assembly coupled to the internal combustion engine. The assembly includes the lever coupled onto the starter shaft disposed in a cover variator of the vehicle, the lever being operable to an engaged position from an idle position for rotating the starter shaft. A gear mechanism is adapted to transfer rotational movement of the starter shaft to a crankshaft of an internal combustion engine of the vehicle. The gear mechanism includes a drive gear mounted onto the starter shaft and a driven gear mounted onto the crankshaft and axially movable thereon. The driven gear includes the helical gear coupled to the drive gear for receiving the rotational movement and the helical ratchet adapted to selectively engage with a crankshaft ratchet for transferring the rotational movement to the crankshaft. The retainer spring is mounted onto the driven gear and is adapted to selectively allow axial displacement of the driven gear on the crankshaft for engagement with the crankshaft ratchet. A stopper member is mounted onto the drive gear and is adapted to selectively engage and disengage with the retainer spring corresponding to rotation of the drive gear. The stopper member is adapted to secure the retainer spring upon engagement, to inhibit axial displacement of the driven gear. While the retainer spring urges axial displacement of the driven gear for coupling with the crankshaft ratchet upon disengagement with the stopper member, to transfer of rotational movement to the crankshaft for kick-starting the vehicle.
[013] In another aspect, a method of assembling the kick starter assembly is disclosed. The method includes coupling the lever onto the starter shaft disposed in a cover variator of the vehicle, the lever operable to an engaged position from the idle position for rotating the starter shaft. The drive gear is mounted onto the starter shaft, while the driven gear is mounted onto the crankshaft and axially movable thereon. The driven gear includes the helical gear coupled to the drive gear for receiving the rotational movement and the helical ratchet adapted to selectively engage with a crankshaft ratchet for transferring the rotational movement to the crankshaft. The retainer spring is then mounted onto the driven gear and adapted to selectively allow axial displacement of the driven gear on the crankshaft for engagement with the crankshaft ratchet. A stopper member is thereafter mounted onto the drive gear to selectively engage and disengage with the retainer spring corresponding to rotation of the drive gear, wherein, the stopper member is adapted to secure the retainer spring upon engagement, to inhibit axial displacement of the driven gear. The retainer spring further urges axial displacement of the driven gear for coupling with the crankshaft ratchet upon disengagement with the stopper member, to transfer of rotational movement to the crankshaft for kick-starting the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS
[014] 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 is a schematic view of a vehicle, in accordance with an exemplary embodiment of the present invention.
Figure 2 is a schematic view of a kick starter assembly mounted to an internal combustion engine of the vehicle, in accordance with an exemplary embodiment of the present invention.
Figure 3 is an exploded view of the kick starter assembly, in accordance with an exemplary embodiment of the present invention.
Figure 4 is an exploded view of the kick starter assembly, in accordance with an exemplary embodiment of the present invention.
Figure 5 is a perspective view of the kick starter assembly, in accordance with an exemplary embodiment of the present invention.
Figure 6 is a top view of the kick starter assembly, in accordance with an exemplary embodiment of the present invention.
Figure 7 is a flow diagram of a method of assembling the kick starter assembly, in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[015] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[016] Figure 1 illustrates a schematic view of a vehicle 200, in accordance with an embodiment of the present invention. As an example, the motor vehicle 200 is a scooter type vehicle. The vehicle 200 has a prime mover 208 [for e.g. as shown in Figure 2] that is disposed behind a floorboard 220 and below a seat assembly 210 and/or a storage bin (not shown). The prime mover 208 is one of an internal combustion engine or an electric motor adapted to provide motive force for vehicle movement. The vehicle 200 has a front wheel 212, a rear wheel 214 and a frame member [not shown] and a fuel tank (not shown).
[017] A head pipe [not shown] connects to the frame member. The head pipe supports a steering shaft [not shown] and a front suspension [not shown] attached to the steering shaft through a lower bracket [not shown]. The front suspension support the front wheel 212. The upper portion of the front wheel 212 is covered by a front fender 216 mounted to the front suspension. In an embodiment, the front fender 216 is movable along with the front wheel 212, during travel over undulations on a road surface. A handlebar 218 is fixed to upper bracket (not shown) and can rotate about the steering shaft for turning the vehicle 200. A headlight 222 and an instrument cluster [not shown] is arranged on an upper portion of the head pipe.
[018] Further, the fuel tank is mounted below the floorboard 220 of the vehicle 200. A rear suspension [not shown] is provided to the rear wheel 214 for dampening the vibrations induced during travel of the vehicle 200 over undulations on the road surface. A taillight unit 224 is disposed at the end of the vehicle 200 and at the rear of the seat assembly 210. A grab rail 226 is also provided for facilitating the grip and/or balance to the rider on the vehicle 200 during movement. The rear wheel 214 is arranged below the seat assembly 210 and adapted to receive the motive force from the prime mover 208. A suitable transmission assembly is provided for transferring the drive force from the prime mover 208 onto the rear wheel 214 for driving the vehicle 200. In an embodiment, the driving force of the prime mover 208 is transmitted through a chain drive [not shown]. A rear fender 228 is disposed above the rear wheel 214. An exhaust pipe (not shown) is also provided for the prime mover 208 of Internal combustion engine type, that extends therefrom towards the rear end of the vehicle 200.
[019] Additionally, a kick start assembly 100 (for e.g. as shown in Figure 5) is mounted to the prime mover 208 of the internal combustion engine type (for e.g. as shown in Figure 2). In the present embodiment, the kick start assembly 100 is provided at a rear-bottom portion of the vehicle 200. The kick start assembly 100 is configured to crank the prime mover 208. The aspects pertaining to the kick start assembly 100 is provided in description pertaining to Figures 3-6.
[020] Figures 3 and 4 illustrate exploded views of the kick start assembly 100 with a cover variator 202, in accordance with an exemplary embodiment of the present disclosure. The assembly 100 is adapted to eliminate noise generated during engagement of ratchet gears during vehicle movement.
[021] Referring to Figure 5 in conjunction with Figures 3 and 4, the kick starter assembly 100 includes a lever 102 mounted on the cover variator 202 (for e.g. as shown in Figure 2) and is coupled to a starter shaft 104. In an embodiment, the lever 102 includes internal splines (not shown) for engaging with outer splines (not shown) on the starter shaft 104. Alternatively, the lever 102 is fastened onto the starter shaft 104. Also, the lever 102 is mounted on outer surface of the cover variator 202, for facilitating access to a user to operate the lever 102 for starting the vehicle 200.
[022] The lever 102 is further operable between an idle position and an engaged position for rotating the starter shaft 104. In an embodiment, the lever 102 is operated between the idle position and the engaged position via a force transmitted via a foot of the user. Accordingly, the lever 102 is positioned at the bottom-rear portion of the vehicle 200, for facilitating its actuation via foot of the user. In an embodiment, the lever 102 is an L-shaped bracket positioned at the bottom-rear portion of the vehicle 200, for facilitating operation via the user’s foot. The L-shaped portion facilitates placement of user’s foot for application of the force for operation between the idle position and the engaged position. The force applied onto the lever 102 is transmitted as rotational movement or torque to the starter shaft 104.
[023] The starter shaft 104 is coupled to a crankshaft 204 of the internal combustion engine 208 via a gear mechanism 106 (as shown in Figure 3). Thus, the rotational movement received by the starter shaft 104 is transferred to the crankshaft 204 via the gear mechanism 106. The gear mechanism 106 includes a drive gear 108 mounted onto the starter shaft 104 and a driven gear 110 mounted onto the crankshaft 204. The driven gear 110 is mounted to be axially displaceable on the crankshaft 204. The driven gear 110 includes a helical gear 110a coupled to the drive gear 108 and a helical ratchet 110b adapted to selectively engage with a crankshaft ratchet 206 for transferring the rotational movement to the crankshaft 204. Thus, upon engagement of the helical ratchet 110b with the crankshaft ratchet 206, the rotational movement received by the drive gear 108 is transferred to the crankshaft 204 via the driven gear 110.
[024] In an embodiment, the size and configuration of the drive gear 108, the helical gear 110a, the helical ratchet 110b are selected based on the requirement of transfer of rotational movement received by the starter shaft 104.
[025] Further, the assembly 100 includes a retainer spring 112 mounted onto the drive gear 108 and is adapted to selectively allow axial displacement of the driven gear 110 on the crankshaft 204. In other words, the retainer spring 112 is configured to selectively allow engagement between the helical ratchet 110b and the crankshaft ratchet 206 for transferring the rotational movement. The retainer spring 112 includes a collar region 116 extending towards the drive gear 108. The collar region 116 includes a fore end 116a supported on a wall 202a of the cover variator 202 and an aft end 116b adapted to engage with a stopper member 114. The stopper member 114 is mounted onto the drive gear 108 and is adapted to selectively engage and disengage with the retainer spring 112, particularly its aft end 116b, corresponding to the rotation of the drive gear 108. For ease of engagement with the aft end 116b of the retainer spring 112, the stopper member 114 is mounted on the drive gear 108 at a location (as shown in Figures 3 and 4) substantially above the aft end 116b.
[026] The stopper member 114 is configured to engage with the retainer spring 112 (for e.g. as shown in Figure 6) in the idle position of the lever 102. Upon engagement, the retainer spring 112 is secured by the stopper member 114, which inherently inhibits axial movement of the driven gear 110 for engagement with the crankshaft ratchet 206, thereby preventing transmission of rotational movement thereto. Such a configuration also prevents unintended contact of the driven gear 110 with the crankshaft ratchet 206 during vehicle movement or engine operating condition, thereby preventing noise generation.
[027] The stopper member 114 is configured to disengage with the retainer spring 112 in the engaged position of the lever 102. In other words, upon application of force onto the lever 102 from the idle position to the engaged position, the stopper member 114 disengages with the aft end 116b. At this juncture, the retainer spring 112 urges axial displacement of the driven gear 110 for coupling with the crankshaft ratchet 206, thereby transferring rotational movement to the crankshaft 204, consequently kick-starting the vehicle 200.
[028] In an embodiment, the stopper member 114 secures the aft end 116b in a stressed state, so that upon disengagement, the retainer spring 112 urges or pushes the driven gear 110 to engage with the crankshaft ratchet 206. Upon transfer of the rotational movement and due to movement of the lever 102 from the engaged position to the idle position, the driven gear 110 rotates in a direction opposite to the direction during engagement with the crankshaft ratchet 206, thereby returning the retainer spring 112 to its stressed state. At this juncture, the aft end 116b engages with the stopper member 114, thereby securing the retainer spring 112.
[029] In an embodiment, the stopper member 114 is made of rubber material. Alternatively, other suitable materials can be employed as per design feasibility and requirement.
[030] In an embodiment, the retainer spring 112 is made of metallic material. Alternatively, the material, configuration and dimensions of the retainer spring 112 is as per stiffness requirement in the kick starter assembly 100.
[031] Figure 7 illustrates a flow diagram of a method 700 for assembling the kick starter assembly 100, in accordance with an exemplary embodiment of the present disclosure.
[032] At step 702, the lever 102 is coupled with the starter shaft 104 which is disposed in the cover variator 202. As already mentioned, the lever 102 is fastened to the starter shaft 104 via internal splines (not shown) provided therein. The lever 102 is mounted to the outer surface of the cover variator 202, while being connected to the starter shaft 104, for facilitating access to the user for actuating the lever 102 between the idle position and the engaged position.
[033] At step 704, the drive gear 108 is mounted onto the starter shaft 104. In the present embodiment, the drive gear 108 is coaxially mounted, by conventional mounting techniques such as press-fitting, on the starter shaft 104. Also, in the present embodiment, the drive gear 108 is semi-circular in configuration. Alternatively, the configuration of the drive gear 108 is selectable as per design feasibility and requirement.
[034] At step 706, the driven gear 110 is mounted, by conventional mounting techniques such as press-fitting, onto the crankshaft 204 of the internal combustion engine 208. In an embodiment, the driven gear 110 is mounted onto the crankshaft 204 via an auxiliary shaft 202b (for e.g. as shown in Figure 6) coupled to the crankshaft 204 via splines. Such a construction enables the driven gear 108 to axially displace (via the auxiliary shaft 202b on the crankshaft 204) for selective engagement and disengagement with the crankshaft ratchet 206. Further, the driven gear 110 is mounted such that, the helical gear 110a meshes with the drive gear 108 for receiving the rotational movement and the helical ratchet 110b selectively engages or meshes with the crankshaft ratchet 206 for transferring the rotational movement to the crankshaft 204.
[035] At step 708, the retainer spring 112 is mounted onto the driven gear 110, particularly between the helical gear 110a and the helical ratchet 110b. The retainer spring 112 is configured with the collar region 116 which has a fore end 116a supported on the wall 202a and an aft end 116b. In an embodiment, the collar region 116 refers to looped configuration of the retainer spring 112.
[036] At step 710, the stopper member 114 is mounted on the drive gear 108 at a position substantially above the aft end 116b. The stopper member 114, in the present embodiment, is a hook member which engages with the aft end 116b. Such a construction is adapted to engage with the aft end 116b for securing the retainer spring 112. Also, due to the position of the stopper member 114, the aft end 116b engages with the stopper member 114 when the lever 102 is in idle position and the aft end 116b disengages from the stopper member 114 when the lever 102 is in engaged position. In an embodiment, the configuration and/or dimensions of the stopper member 114 is selected such that the retainer spring 112 is retainer for a predetermined rotation of the lever 102. In other words, the aft end 116b is engaged with the stopper member 114 for the predetermined rotation of the lever 102 during its actuation from idle position to the engaged position.
[037] Advantageously, the present invention provides the kick starter assembly 100 which prevents engagement of the driven gear 110 with the crankshaft ratchet 206 during engine running or vehicle movement, thereby eliminating generation of noise. Consequently, the reliability and durability of the assembly 100 is enhanced.
[038] 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.