Electrical starter system for motorcycles

Abstract

An electric starter system (100) for a motorcycle, particularly a Harley-Davidson brand motorcycle, having a four-speed transmission, with a mechanical kick-start starting device (200), the motorcycle having a transmission main shaft (340) that rotates in a predetermined starting / driving rotational direction (x) when starting the motorcycle and during normal operation of the motorcycle, the kick-start starting device (200) having a kicker pinion and a kicker clutch portion (240), the kicker pinion configured to axially couple with the kicker clutch portion (240), the kicker clutch portion (240) being in contact with the transmission main shaft (340), the kicker pinion being configured to axially couple with the kicker clutch portion (240), the kicker clutch portion (240) being in contact with the transmission main shaft (340), the kicker pinion being configured to axially couple with the kicker clutch portion (240), the kicker clutch portion (240) being in contact with the transmission main shaft (340), the kicker pinion being configured to axially couple with the kicker clutch portion (240), the kicker pinion being configured to axially couple with the kicker clutch portion (240) and ... pinion and the kick It is desirable to provide a solution for improving electric starter systems for motorcycles, particularly for motorcycles equipped with kick-start starting devices, by making it possible to retrofit or install electric starter systems with only minor modifications to the original components, with minimal time and effort, and / or more easily or quickly, in an electric starter system (100) that includes an electric starter motor (110) having a starter shaft pinion (112) drivable by the electric starter motor (110). This is achieved by allowing the torque of the electric starter motor (110) to be transmitted from the starter shaft pinion (112), preferably frontally, to the kicker clutch part (240), particularly via an intermediate connected starter transmission (120).

Description

[Technical field]

[0001] The present invention provides an electrical starter system for a motorcycle having a mechanical kick start type starting device, particularly for a Harley-Davidson brand motorcycle having a four-speed transmission, comprising: The motorcycle has a transmission main shaft that rotates in a predetermined starting / driving rotational direction when the motorcycle is started and during normal operation of the motorcycle, the kick start starting device has a kicker pinion and a kicker clutch portion, the kicker pinion is configured for axial connection with the kicker clutch portion, the kicker clutch portion is coupled to the transmission main shaft to transmit torque, and the electric starter system includes an electric starter motor having a starter shaft pinion drivable by the starter motor.

[0002] The present invention further relates to an electric starter set for retrofitting motorcycles equipped with mechanical kick-start starting systems, particularly Harley-Davidson brand motorcycles equipped with four-speed transmissions.

[0003] The invention further relates to a motorcycle which is equipped, retrofitted or can be retrofitted with an electric starter system according to the invention or with an electric starter set according to the invention. [Background technology]

[0004] The present invention belongs to the field of motorcycles with internal combustion engines, where a "motorcycle" is a motorized two-wheeled vehicle, including, for example, a scooter or a moped. Unlike an electric motor, an internal combustion engine cannot be started by itself. Therefore, in order to start an internal combustion engine, it is necessary to "crank" the internal combustion engine by performing at least one intake and compression stroke by an external force. That is, it is necessary to energize the crankshaft of the internal combustion engine until it reaches the minimum rotation speed required for starting. The energization of the crankshaft is performed via a device called a "starter". Many starters are configured in the form of an electric motor, also called an "electric starter". This electric starter is operated, for example, via a start button provided on the steering or on the electric motor itself, and the torque of the electric starter is transmitted to the crankshaft to start the internal combustion engine.

[0005] Mechanical starters are also used, particularly for small internal combustion engines such as those used in motorcycles. Well-known mechanical starters are in the form of mechanical kick-start starting devices, or so-called "kick starters".

[0006] A kick starter is usually a lever consisting of a kick start pedal and a kicker shaft. When the rider presses the kick start pedal forcefully with his foot, the kicker shaft is set into a rotational motion, which is then transmitted to the crankshaft, thereby providing the required RPM for starting the internal combustion engine. In particular in the case of motorcycles of the Harley-Davidson brand, for example, the internal combustion engine and the transmission are often housed in separate housings ("Big Twin"). Thus, in addition to the direct transmission to the crankshaft, the rotational motion is also transmitted indirectly via the transmission main shaft of the motorcycle transmission. In this case, the torque manually generated on the kicker shaft is first transmitted to the motorcycle transmission main shaft, which then transfers this rotational motion to the crankshaft of the internal combustion engine via a so-called primary drive by means of a chain or belt.

[0007] For the starting or starting process, the transmission main shaft is rotated in a defined starting / driving direction of rotation, and thus also the crankshaft. The starting / driving direction of rotation corresponds to the direction in which the crankshaft or the transmission main shaft rotates during normal operation of the motorcycle, i.e. when the internal combustion engine is running and / or when driving forward. Very rarely, motorcycles are also equipped with a reverse gear. When driving backwards, driven by the internal combustion engine, the crankshaft and the transmission main shaft also rotate in the above-mentioned starting / driving direction of rotation. The direction of travel is changed by shifting the transmission into reverse gear.

[0008] In contrast, if the motorcycle is manually pushed backwards, for example by muscle force applied by the rider, leaving the forward gear engaged would transmit the rotation of the rear wheel through the secondary chain to the transmission main shaft, causing the transmission main shaft to rotate in the reverse direction, opposite to the starting / driving direction. Engaging the neutral gear directly prevents the transmission main shaft from rotating when the motorcycle is pushed backwards.

[0009] In order to avoid the kick start pedal from "turning together" during the starting process or after the starting process and / or during normal operation of the motorcycle and to allow the kick start pedal to return to its initial position, the kicker shaft and the transmission main shaft are releasably coupled to each other via a clutch coupling of the kick start starter, i.e., a "kicker clutch". The kicker clutch is formed of a kicker clutch part fitted to the transmission main shaft so as to transmit torque and a kicker pinion arranged to be positioned axially opposite each other, where the kicker clutch part has an axially arranged, inclined, orthogonal tooth arrangement (also called a "kicker ratchet") and the kicker pinion has a corresponding, complementary orthogonal tooth arrangement. The kicker pinion is rotatably supported on the transmission main shaft, in particular via a bronze bush, and is arranged to mesh with the kicker gear by its front tooth arrangement.

[0010] The kicker gear is also torque-transmittingly fastened, particularly in a friction-locking and / or positive-locking manner, to a kicker shaft, on which, as explained above, a kick-start pedal is attached. Due to the intermeshing orthogonal tooth arrangement between the kicker clutch part, which forms a freewheel in the driving rotation direction of the transmission main shaft, and the kicker pinion, the kick-start pedal is prevented from rotating along with it immediately after the starting process. During standard operation, i.e. when the internal combustion engine is running, the kicker clutches are axially decoupled from one another.

[0011] Before the invention of the electric starter, kick starters were necessary. Kick starters have been used to start internal combustion engines on motorcycles for several decades. Even today, a great many older motorcycles, especially those under the Harley-Davidson brand, are equipped with kick starters.

[0012] For convenience reasons, there is a demand for retrofitting older motorcycles equipped with kick-start starting devices with electric starter systems. At the same time, enthusiasts place great importance on maintaining the full functionality of the original kick-starter when retrofitting with an electric starter and replacing or modifying as few original components or parts of the motorcycle as possible.

[0013] From the prior art, for example from DE 202016104454 A1, electric starter systems are known for retrofitting motorcycles of the Harley-Davidson brand with a kick starter. In order to make efficient use of the construction space available in the original motorcycle, various modifications have been made to integrate the electric starter system, mainly on the left side in the direction of travel of the motorcycle.

[0014] The function of the original kick starter, which normally supplies torque to the transmission main shaft via a kicker clutch on the right side of the motorcycle, is maintained. On the left side of the motorcycle, the torque of the electric motor is transferred to the transmission main shaft by a modified clutch hub. This clutch hub is welded to an additional starter ring gear, with which the starter shaft pinion of the electric motor meshes during the starting process. In order to provide the required construction space for the starter ring gear, the entire motorcycle clutch on the transmission main shaft must be repositioned to the left in the direction of travel. In order to achieve the required alignment, the output pinion of the internal combustion engine itself must also be repositioned to the left. Other modifications require the installation of an additional chain tensioner as well as adjustments to the original oil tank. [Prior art documents] [Patent documents]

[0015] [Patent Document 1] German Utility Model No. 202016104454 Summary of the Invention [Problem to be solved by the invention]

[0016] The object of the present invention is to improve an electric starter system for a motorcycle, in particular to make it possible to retrofit or install an electric starter system on a motorcycle having a kick-start starting device easily and quickly with only minor changes to the original components and in a short time. [Means for solving the problem]

[0017] This problem is solved by an electric starter system according to claim 1, an electric starter set according to claim 10 and a motorcycle according to claim 15.

[0018] A starter system according to the invention of the type mentioned at the beginning is characterized in that the torque of the electric starter motor can be transmitted from the starter shaft pinion, preferably on the front side, to the kicker clutch part, in particular via an intermediate connected starter gear.

[0019] That is, in accordance with the present invention, the torque required to start the internal combustion engine is provided by an electric starter motor and transmitted to the transmission main shaft via a kicker clutch portion of a mechanical kick-start starter. This has been found to be particularly advantageous because the kicker clutch portion, as a component of the kick-start starter, is integrally or torque-transmittingly coupled to the transmission main shaft for transmitting torque from the kick starter to the transmission main shaft.

[0020] By using the same torque transmission method for the motorcycle to transmit the torque applied by the electric starter motor to the transmission main shaft, the number of modifications to be made to the original components and / or the number of original components to be replaced are minimized. In particular, no additional components such as gears or ring gears need to be coupled to the transmission main shaft.

[0021] According to the invention, the necessary adaptations or modifications are made only on the side of the motorcycle on which the mechanical kick-start starting device is installed, which is usually the right side in the direction of travel of the motorcycle. This makes it possible to avoid, for example, rearrangement of the motorcycle clutch. This makes previously necessary adaptations, such as the incorporation of a chain tensioner, and / or modifications to the output pinion of the internal combustion engine unnecessary. No modifications to the original components of the motorcycle are necessary, apart from the components of the mechanical kick-start starting device. This is particularly advantageous, since the adaptation of the kick-start starting device can be realized significantly more simply and without hassle than, for example, a clutch or a clutch cage and / or a primary drive.

[0022] Since the electric starter system acts on the kicker clutch portion itself or acts on the kicker clutch portion to transmit torque, the electric starter system according to the present invention can be constructed in a more compact structure and / or the electric starter motor can be made smaller.

[0023] Therefore, the electric starter system according to the present invention can be incorporated into a mechanical kick-start starting device by making structural changes that are almost invisible from the outside, so that the appearance of the motorcycle remains almost unchanged. Therefore, for owners of motorcycles, particularly old Harley-Davidson-class motorcycles that are also traded among enthusiasts as collection items, an optimal compromise can be achieved in terms of ride comfort, almost complete preservation of the original components and their functionality, and visual appearance. Therefore, the electric starter system according to the present invention can be particularly advantageously applied as a starting aid for four-speed big twin Harley-Davidson motorcycles.

[0024] Advantageous embodiments of the invention are set forth in the respective dependent claims and are explained in more detail below.

[0025] In motorcycles with kick starters, the torque of the mechanical kick-start starting device is usually transmitted axially via the kicker clutch, i.e. via axially arranged, mutually complementary orthogonal tooth rows, between the kicker pinion and the kicker clutch part. In order to optimally utilize the available construction space, it is therefore advantageous for the torque of the electric starter motor to also be transmitted to the kicker clutch part on the front side, in particular via a cylindrical gear transmission, which is called the "starter gear" of the electric starter system. The starter gear can be connected between a starter shaft pinion attached to the output of the electric starter motor and the kicker clutch part.

[0026] That is, in one advantageous embodiment of the present invention, the electric starter motor may be arranged axially parallel to the transmission main shaft, and the torque of the electric starter motor may be transmittable to a kicker clutch portion coupled to transmit torque to the transmission main shaft via one or more stages of an intermediately connected starter transmission, preferably a cylindrical gear transmission, provided in the electric starter system.

[0027] In this embodiment, the electric starter motor is arranged behind the transmission in the direction of travel of the motorcycle, and the transmission main shaft and the starter shaft of the electric starter motor are oriented parallel to one another. Starting from a starter shaft pinion on the starter shaft of the electric starter motor, the torque is transmitted via a preferably multi-stage starter gear to the kicker clutch part and from there to the transmission main shaft. By means of a corresponding gear ratio, on the one hand, the starter gear serves to convert the rotational speed of the electric starter motor into the torque required by the transmission main shaft, and on the other hand, the distance between the starter shaft of the electric starter motor and the transmission main shaft is also compensated. For this purpose, it is expedient if the starter gear is designed as a cylindrical gear gear, so that the torque can be transmitted to the kicker clutch part on the front side. In this way, a compact design of the starter gear and thus of the entire electric starter system can be achieved. As the torque is transmitted overall via a shorter path, a particularly gentle and quiet start of the internal combustion engine can be achieved.

[0028] As in another embodiment of the invention, it is advantageous if the electric starter system has a starter ring gear which coaxially surrounds the kicker clutch part for torque-transmitting meshing with a starter gear of a starter transmission, in particular a cylindrical gear transmission, or for torque-transmitting meshing with a starter shaft pinion of an electric starter motor.

[0029] In this embodiment, the kicker clutch part is provided with a ring gear, called the "starter ring gear", along its periphery, i.e., on its front side, which is designed to mesh with a gear, called the "starter gear", of the starter transmission. Preferably, the starter gear and the starter ring gear are connected to each other on the front side or form a meshing gear pair.

[0030] In order to prevent the rotation of the crankshaft being transmitted back to the electric starter motor via the transmission main shaft during operation of the internal combustion engine, i.e. during normal operation of the motorcycle, which would result in unintended rotation of the electric starter motor or even damage to the starter motor, it is functionally advantageous if, as in one embodiment of the invention, the electric starter system comprises a starter freewheel device, which is intermediately connected between the electric starter motor, in particular the starter shaft pinion, and the kicker clutch part, so that in the starting / driving rotation direction of the transmission main shaft, starting from the electric starter motor towards the kicker clutch part, a torque-transmitting clutch is formed, and in the direction starting from the kicker clutch part towards the electric starter motor, a free-running clutch is formed.

[0031] In order to achieve a complete decoupling between the electric starter motor and the kicker clutch part, it is conceivable, for example, to allow an axial displacement between the starter shaft pinion and the kicker clutch part. In particular, the starter shaft pinion and / or the starter pinion meshing with the starter gear can be designed to be linearly movable, whereby the starter shaft pinion and / or the starter pinion are arranged to mesh with each other in order to transmit torque and rotational motion from the electric starter motor to the kicker clutch part, or are arranged offset with respect to each other in order to prevent the transmission of torque and rotational motion from the kicker clutch part to the electric starter motor. Alternatively, as a more space-saving configuration, the starter freewheel device can also be arranged to coaxially surround the kicker clutch part.

[0032] Therefore, in an improved version, the starter freewheel device is configured in the form of a sprag freewheel or roller sprag freewheel, in particular a rolling bearing freewheel, which coaxially surrounds the kicker clutch part, in which case the rotational movement of the transmission main shaft is blocked, in particular in the reverse direction opposite to the starting / driving rotation direction.

[0033] In this case, it is particularly expedient if the starter freewheel device has a radially outer race and a radially inner race, the radially outer race being connected to a starter ring gear of the electric starter system in a torque-transmitting manner and the radially inner race being connected to a kicker clutch part of the kick-start starting device in a torque-transmitting manner.

[0034] The starter freewheel device is preferably designed as a one- or two-row rolling element freewheel. In this case, one or two rolling passages are provided correspondingly between the radially outer race and the radially inner race, inside which the rolling elements, in particular cylinders or balls, are arranged. In the starting / driving rotation direction of the transmission main shaft and for starting the internal combustion engine, i.e. when it is desired to transmit the rotational movement of the electric starter motor to the transmission main shaft, the rolling element freewheel is in a "clamped state", whereby the relative movement between the radially outer race and the radially inner race is blocked. This allows the transmission of the rotational movement or torque of the electric starter motor from the starter freewheel device to the kicker clutch part and thus to the transmission main shaft connected to the kicker clutch part.

[0035] As soon as the internal combustion engine is started and the transmission main shaft is driven by the internal combustion engine or the rotational speed of the radially inner race exceeds the rotational speed of the radially outer race, the starter freewheel device automatically disengages and the rolling elements roll freely inside the rolling passages, so that the kicker clutch part, which is firmly attached to the transmission main shaft, rotates together with the transmission main shaft. However, this rotational movement or torque is not transmitted to the radially outer race or to the starter ring gear connected to this race. The starter freewheel device in this case acts as an overrunning clutch. If such a starter freewheel device, which is particularly advantageously configured as a rolling bearing freewheel, is provided between the starter gear and the transmission main shaft of the motorcycle, damage to the electric starter motor is prevented. In addition, the rolling bearing freewheel has a high running quietness, so that only low noise is generated overall during the starting process and during normal operation with the internal combustion engine in operation.

[0036] Additionally, in an optional variant of the invention, the starter freewheel device may also have the function of a reverse lock. In this case, rotational movement of the transmission main shaft is only possible in the starting and driving direction of rotation, whereas reverse rotational movement in the opposite reverse direction is locked. In the reverse direction of the transmission main shaft, the rolling element freewheel is "clamped" as long as a torque is applied to the radially inner race. In particular, due to the intermediate connected multi-stage starter gearing, which exerts a deceleration effect in this direction, a sufficiently high operating resistance is generated, so that the transmission main shaft is locked in the reverse direction by the starter freewheel device. This function has the advantage that unintended rotation of the electric starter motor in the reverse direction is prevented. The motorcycle can then be pushed backwards by shifting into neutral, i.e. by decoupling the transmission main shaft from the rear wheel.

[0037] In yet another advantageous embodiment of the present invention, the electric starter system has an adapter plate disposed between a cover of the kick start starter and a transmission housing of the motorcycle, and the electric starter motor is attached to the transmission housing of the motorcycle by means of the adapter plate.

[0038] In order to accommodate the electric starter motor as space-savingly as possible within the available construction space, it is expedient to mount the electric starter motor behind the motorcycle transmission in the direction of travel of the motorcycle, preferably behind the transmission housing. The attachment of the electric starter motor is preferably realized by means of an adapter plate which is arranged on the side of the motorcycle having the mechanical kick-start starting device, usually on the right side of the motorcycle in the direction of travel of the motorcycle, on the transmission housing and is in particular screwed to the transmission housing, for example via a stud bolt. For this purpose, the adapter plate should have a peripheral contour which substantially corresponds to the peripheral contour of the kick-start starting device cover, also called "kicker cover", so that the adapter plate fits flush with the kicker cover.

[0039] Additionally, the adapter plate has a lateral extension, which is formed as a mounting section, with which it is connected, in particular by screwing, to the electric starter motor. The adapter plate is therefore preferably formed with a minimum thickness of, for example, 10 mm, in order to form the only connection to the electric starter motor and to be able to withstand the torques and forces that arise at the connection points. Preferably, the adapter plate has a thickness of 15 to 20 mm, particularly preferably a thickness of about 20 mm.

[0040] Due to the adapter plate, the distance between the kick start cover and the housing cover is increased. Therefore, in order to attach the kick start cover to the housing cover with the adapter plate in between in the recess in the original transmission housing, it is preferable to use a mounting means, in particular a stud bolt, which is longer than the original mounting means. For this reason, in many types of motorcycles, an adjustment of the exhaust system is also necessary. Advantageously, a seal is provided between the kick start cover and the adapter plate and between the adapter plate and the transmission housing.

[0041] Furthermore, another advantageous function of the adapter plate is the protection and accommodation of the starter gear, the starter freewheel device and / or the kicker clutch part.

[0042] In a refinement of the above-described embodiment, it is therefore expedient if the adapter plate has and / or forms a receiving area for receiving the starter freewheel device and / or for receiving the starter ring gear.

[0043] Additionally, the adapter plate can be connected, in particular releasably, to one or more starter coupling pieces which are provided for receiving further transmission elements of the starter gear and / or for coupling to an electric starter motor, in particular to a starter shaft pinion on its output side, and which together form a starter gear housing.

[0044] In order to facilitate the retrofitting of older motorcycles, particularly big twin Harley Davidson motorcycles with four-speed transmissions, with an electric starter system and to simplify the installation and removal or replacement of defective and / or worn components with alternative parts, in a variant of the invention, the electric starter system may have a kicker shaft with a removable spring seat for receiving a kickstart spring, the kicker shaft being configured for torque-transmitting coupling to a kicker gear.

[0045] In the original design of the mechanical kick-start starting device, the kick-start cover, i.e. the kicker cover, is intended to be removed together with the kicker shaft and the kicker gear which is attached to transmit torque to the kicker shaft. However, due to the additional components provided in the kicker clutch part of the electric starter system according to the invention, in particular the starter ring gear and / or the starter freewheel device, which respectively coaxially surround the kicker clutch part, the circumference of the kicker clutch part is enlarged compared to the kicker ratchet of the original components. As a result, the kicker gear overlaps along the kicker shaft before the kicker clutch part, so that it is no longer possible to remove the kicker shaft together with the kicker gear and together with the kicker cover.

[0046] A means for avoiding this problem is provided in that the spring seat to which the kicker spring is attached is designed to be removable or detachable from the kicker shaft. In order to allow access to the original components of the kick-start starter that are arranged behind the kicker cover and to the components of the electric starter system, in this embodiment the kicker cover or kick starter cover can be pulled out over the kicker shaft for retrofitting, conversion and component replacement without removing the kicker shaft itself, by first removing the spring seat.

[0047] In order to equip a motorcycle, particularly a Harley-Davidson brand motorcycle with a four-speed transmission, with an electric starter system and at the same time maintain the functionality of the mechanical kick-start starter, it is expedient if the original motorcycle can be retrofitted with an electric starter system according to the invention, where the electric starter system is at least partially integrated into the mechanical kick-start starter.

[0048] The problem posed at the outset is therefore solved by an electric starter set for retrofitting a motorcycle with a mechanical kick-start starter, in particular a motorcycle of the Harley-Davidson brand with a four-speed transmission, having a transmission main shaft which rotates in a defined starting and driving rotational direction when the motorcycle is started and during normal operation of the motorcycle.

[0049] According to the invention, the electric starter set comprises an electric starter motor with a starter shaft pinion drivable by the electric starter motor, a kicker clutch part with a starter freewheel device designed for torque-transmitting coupling to a transmission main shaft, the starter freewheel device designed for connecting the kicker clutch part with the starter shaft pinion, in particular at the front side, and an adapter plate designed for coupling the electric starter motor to a transmission housing of the motorcycle and / or for accommodating the kicker clutch part with the starter freewheel device.

[0050] That is, according to the invention, the kicker clutch part itself is a component of an electric starter set and is designed for axial meshing with a kicker pinion of a mechanical kick-start starting device and for torque-transmitting connection with an electric starter motor at the front side. The kicker clutch part further preferably comprises an integrated starter freewheel device. In particular, the starter freewheel device may coaxially surround the kicker clutch part in the form of a rolling-bearing freewheel, the radially inner race being connected to the kicker clutch part in a form-locking and / or friction-locking manner in a torque-transmitting manner. In an alternative embodiment, the kicker clutch part and the radially inner race may be formed in one piece. Preferably, the front side of the radially outer race has an outer toothing formed like a ring gear or is connected in a form-locking and / or friction-locking manner in a torque-transmitting manner to a ring gear which coaxially surrounds the radially outer race.

[0051] The kicker clutch part has an orthogonal toothing in the axial direction, which is complementary to the orthogonal toothing of the original kicker pinion and can mesh with the orthogonal toothing of the original kicker pinion. The orthogonal toothing creates a freewheel between the kicker clutch part and the kick starter in the driving rotation direction of the transmission main shaft, and the starter freewheel device is provided for creating a freewheel between the kicker clutch part and the electric starter motor, also in the driving rotation direction of the transmission main shaft. The kicker clutch part with the integrated starter freewheel device therefore forms the central connecting element between the electric starter system and the mechanical kick-start starting device.

[0052] In an advantageous embodiment, an electric starter set is pre-assembled, in which the adapter plate is preferably detachably connected to the electric starter motor, in particular via one or more starter connecting pieces, and / or the kicker clutch part with the starter freewheel device is arranged inside a receiving area provided in the adapter plate and designed for this purpose.

[0053] Since at least most of the components of the electric starter set are already pre-assembled, retrofitting to the motorcycle is significantly easier. The conversion or assembly of the electric starter set to the mechanical kick-start starter can be performed by the user himself without special expertise and / or special tools, such as welding equipment, and does not necessarily require a visit to a specialist workshop.

[0054] In yet another advantageous variant, the electric starter set includes a starter gear and a starter ring gear, the starter ring gear being arranged coaxially surrounding the kicker clutch part and the starter freewheel device, and the starter gear is configured and arranged as a component of the starter transmission device to mesh with a starter shaft pinion of the electric starter motor and to mesh with the starter ring gear.

[0055] In order to make retrofitting, removal and installation as simple and trouble-free as possible, in a preferred embodiment of the invention, the electric starter set additionally includes a kicker shaft with a removable spring seat, which is designed for torque-transmitting connection to a kicker gear provided in the kick-start starting device.

[0056] In further embodiments, as additional components for compensation of the adapter plate to be arranged between the transmission housing and the kicker cover, the electric starter set may have a kicker shaft and / or a brake shaft and / or a transmission clutch operating lever and / or a clutch pushrod, respectively, in order to be optionally and / or selectively replaced with the corresponding original components of the motorcycle.

[0057] Compared to the original components, the kicker shaft and / or the brake shaft and / or the transmission clutch operating lever and / or the clutch push rod are each preferably extended by the thickness of the adapter plate, in particular by 10 to 20 mm.

[0058] Furthermore, the problem posed at the outset is also solved according to the invention by a motorcycle which is equipped, retrofitted or provided with an electric starter system according to one of the above-mentioned embodiments or an electric starter set according to one of the above-mentioned variants.

[0059] Further details, features, combinations, advantages and operation of the invention will become apparent from the following description of preferred embodiments of the invention with reference to the drawings. [Brief description of the drawings]

[0060] [Figure 1] FIG. 1 is a schematic perspective view of an exemplary embodiment of an electric starter system according to the present invention, as assembled to a motorcycle transmission housing using an adapter plate, but without the kick-start starter cover. [Diagram 2] FIG. 2 is a schematic perspective view showing the adapter plate shown in FIG. 1 alone. [Diagram 3]FIG. 2 is a schematic exploded perspective view of the exemplary embodiment of the electric starter system according to the present invention shown in FIG. 1 with a kick start starter cover; [Figure 4] 2 is a schematic side view of the exemplary embodiment of the electric starter system according to the invention shown in FIG. 1, without the adapter plate. [Diagram 5] 2 is a schematic perspective view of the exemplary embodiment of the electric starter system according to the invention shown in FIG. 1, seen from the transmission housing side. [Figure 6] FIG. 1 is a schematic exploded perspective view of an exemplary embodiment of an electric starter set according to the present invention, shown assembled to a cover of a kick-start starter; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0061] The drawings are merely exemplary and are provided for the understanding of the invention. Identical elements are provided with the same reference numerals.

[0062] 1 is a schematic perspective view of an exemplary embodiment of an electric starter system 100 according to the present invention, assembled to a transmission housing 310 of a motorcycle (not shown) using an adapter plate 150. The figure is shown as viewed obliquely from above, on the front of the motorcycle and the side of the mechanical kick-start starter 200, which in this case is typically positioned on the right side of the motorcycle in the direction of travel.

[0063] Besides the adapter plate 150, the electric starter system 100 includes an electric starter motor 110 and a starter gear 120, which is arranged inside a starter gear housing 130. The electric starter motor 110 is arranged behind a transmission housing 310 in the direction of travel of the motorcycle. The transmission housing 310 encloses the main components of the motorcycle transmission 300 and is mounted on a transmission base plate 330. The adapter plate 150 has an outer peripheral surface that substantially corresponds to the contour of the peripheral surface of an adapter part 320 mounted on the transmission housing 310 and is matingly attached to said adapter part 320, for example by means of screws or studs. The figure also shows a transmission clutch operating lever 350 and a clutch pushrod 360.

[0064] Further components of the mechanical kick-start starter 200 are arranged in the adapter part 320 of the transmission housing 310, in particular the kicker gear 220. The kicker gear 220 is connected to the kicker shaft 210 in a form-locking and / or friction-locking manner for torque transmission. The kicker shaft 210 protrudes from a kidney-shaped recess 151 in the adapter plate 150 and has at its outer end a pedal connection 211 for a form-locking attachment of a kick-start pedal (not shown). The kicker shaft 210 is further provided with a spring seat 212 for connection to a kicker spring (also not shown). Preferably, the spring seat 212 can be removed from the kicker shaft 210 via the pedal connection 211. For this purpose, the spring seat 212 is detachably connected to the kicker shaft 210, in particular by means of a set screw 213. The kicker pinion, not visible in the drawings, is rotationally supported on a transmission main shaft 340 (also not visible in the drawings) of the transmission 300 for meshing with the kicker gear 220. The kicker pinion forms a kicker clutch together with a kicker clutch portion 240, which is either non-rotatably coupled to the transmission main shaft 340 for transmitting torque or is coupled to the transmission main shaft 340 for transmitting torque.

[0065] Fig. 2 is a schematic perspective view showing the adapter plate 150 shown in Fig. 1 in isolation. In the assembled state, the adapter plate 150 comprises a kidney-shaped recess 151 pierced by the kicker shaft 210, a receiving area 152 formed and shaped to receive the kicker clutch part 240, and a mounting part 153 provided for mounting the electric starter motor 110, which mounting part 153 forms a closing piece of the starter transmission housing 130. The adapter plate 150 therefore constitutes the only connection between the electric starter motor 110 and the transmission housing 310 via the mounting part 153. In other words, the electric starter motor 110 is only attached to the mounting part 153 of the adapter plate 150. In order to be able to withstand the torque exerted by the starter motor 110 and the forces arising between the mounting part 153 and the receiving area 152, the adapter plate is formed with a minimum thickness, at least at this point, of e.g. 10 mm. Preferably, the adapter plate has a thickness of 15 to 20 mm, particularly preferably a thickness of approximately 20 mm.

[0066] 3 is a schematic exploded perspective view of an exemplary embodiment of the electric starter system 100 according to the present invention shown in FIG. 1, and additionally shows the cover 250 of the mechanical kick-start starter 200. The view is drawn as viewed obliquely from the motorcycle rear and the kick-start starter 200 side.

[0067] An adapter plate 150 is arranged between the cover 250 and the transmission housing 310, so that the initial gap between the two original components (cover 250 and transmission housing 310) is increased by the thickness of the adapter plate 150. A mounting means 251 is used to mount the kick start cover 250 with the adapter plate 150 located therebetween inside a cutout provided in the adapter part 320 of the transmission housing 310. As the mounting means 251, a stud bolt with a spring washer and a nut is shown as an example.

[0068] The mounting part 153 of the adapter plate 150 is used to mount the electric starter motor 110 by means of three screws 154. Preferably, the electric starter motor 110 is screw-fastened to the mounting part 153 indirectly via the starter transmission housing 130. The starter transmission housing 130 is formed by two parts, namely a first starter coupling piece 131 corresponding to the mounting part 153 and a second starter coupling piece 132 corresponding to the electric starter motor 110.

[0069] Furthermore, from Fig. 3 one can see part of the starter transmission 120 of the electric starter system 100, which is arranged inside the starter transmission housing 130. The starter transmission 120 comprises a starter pinion 121, which forms a gear pair with a starter gear 122, so that the torque of the electric starter motor 110, which is taken off at the starter shaft pinion 112 of the electric starter motor 110, which is not visible in this drawing, is transmitted on the front side to a kicker clutch part 240 (see also Fig. 5). For this purpose, the outer teeth of the starter gear 122 mesh with a starter ring gear 123 which surrounds the kicker clutch part 240 along its front side. The further components of the starter transmission 120 are shown in Fig. 6 and are explained in more detail in the corresponding places.

[0070] FIG. 4 is a schematic side view of an exemplary embodiment of the electric starter system 100 according to the present invention shown in FIG. 1. In FIG. 4, the direction of rotation of the transmission main shaft 340 is shown. To start the internal combustion engine, the transmission main shaft 340 is rotated in a starting / driving rotational direction x by the electric starter system 100 or, as an alternative, by a mechanical kick-start starter 200. During standard driving operation or even while the internal combustion engine is running, the transmission main shaft 340 rotates in the starting / driving rotational direction x together with the crankshaft. In contrast, if the motorcycle is pushed backwards, and if the gears are engaged, the rotational motion of the rear wheel will be transmitted to the transmission main shaft 340 in the opposite, reverse direction y.

[0071] A kicker clutch part 240 is supported on the transmission main shaft 340 so as to transmit torque. The kicker clutch part 240 is coaxially surrounded by a starter freewheel device 140 configured as a rolling bearing freewheel. The starter freewheel device 140 has a radially inner race 142 and a radially outer race 141, which in the configuration shown in the drawings form two rolling passages as a two-row rolling element freewheel, inside which rolling elements 143, balls in this embodiment, are arranged.

[0072] The radially inner race 142 is torque-transmittingly connected to the kicker clutch part 240. This connection can be frictionally and / or form-locking, for example as an interference fit, although it is alternatively conceivable for the kicker clutch part 240 to be formed integrally with the inner race 142. The radially outer race 141 is also torque-transmittingly connected to the starter ring gear 123, also frictionally and / or form-locking, for example as an interference fit, or alternatively integrally.

[0073] The starter ring gear 123 meshes with the outer teeth of the starter gear 122 on the front side. In the starting / driving rotation direction x of the transmission main shaft 340, the starter freewheel device 140 acts as an overrunning clutch and is in a "clamped state" as long as the radially outer race 141 rotates faster than the radially inner race 142. This locks the relative movement between the radially outer race 141 and the radially inner race 142, allowing the transmission of rotational movement and torque from the "radially outer" to the "radially inner".

[0074] That is, for starting the internal combustion engine, the torque generated by the electric starter motor 110 is transferred to the transmission main shaft 340 in the starting-driving rotation direction x. As soon as the rotation speed of the transmission main shaft 340 is high enough or the internal combustion engine is started and drives the transmission main shaft 340 by itself, the radially inner race 142 "overruns" the radially outer race 141, so that the starter freewheel device 140 automatically disengages, i.e. the rolling elements 143 roll freely inside the rolling paths. In this case, the transmission of rotational motion or torque from the "radially inner" to the "radially outer" direction is prevented, and the transmission of rotational motion or torque from the transmission main shaft 340 to the electric starter motor 110 in the starting-driving rotation direction x is prevented, thus preventing damage to the electric starter motor 110.

[0075] In order to prevent the transmission main shaft 340 from rotating in the reverse direction y and thus potentially damaging the electric starter motor 110 when the motorcycle is pushed backwards with a forward gear engaged, the starter freewheel device 140 acts as a "reverse lock" when a forward gear is engaged and conversely is "clamped" when the radially inner race 142 rotates faster than the radially outer race 141 or when reverse rotational motion is transferred from the rear wheel of the motorcycle to the transmission main shaft 340.

[0076] The actual locking of the transmission main shaft 340 in the reverse direction y is then effected via an end stop on the kicker gear 220. For this purpose, the kicker gear 220 is provided with a stop pin 221 which is designed to bear against a corresponding stop surface on the inside of the cover 250 of the kick-start starter 200. The cooperation of the stop pin 221 with the stop surface produces an end stop which, on the one hand, defines the rest position of the kicker gear 220 when driving after the starting process and, on the other hand, locks the transmission main shaft 340 in the reverse direction y.

[0077] Nevertheless, a shift into neutral can be performed as usual in order to be able to push the motorcycle backwards. The kicker gear 220 is arranged behind the starter freewheel device 140 or between the starter freewheel device 140 and the transmission housing 310 as viewed in the drawing direction of FIG. 4 and is partially overlapped by the starter freewheel device 140 with the starter ring gear 123.

[0078] 5 is a schematic perspective view of the exemplary embodiment of the electric starter system 100 according to the invention shown in FIG. 1 from the opposite side, i.e. from the side of the transmission housing 310 (not shown in FIG. 5). In particular, the kicker clutch part 240 is clearly visible. Viewed along a radius starting from the transmission main shaft 340 shown in dashed line, the kicker clutch part 240 is coaxially surrounded first by the radially inner race 142, then by the rolling elements 143, and then by the radially outer race 141, which together form the starter freewheel device 140.

[0079] Finally, there is a starter ring gear 123 with a front tooth arrangement on its outer periphery. The kicker clutch portion 240 has orthogonal teeth 241 in the axial direction, which are complementary to the orthogonal teeth on an original kicker pinion (not shown) of the mechanical kick start starting device 200. The original kicker pinion is rotationally supported on a transmission main shaft 340, shown in dashed lines, and is axially slidable along the transmission main shaft 340 for coupling and meshing with the kicker clutch portion 240.

[0080] To start the internal combustion engine of the motorcycle, the torque generated by the mechanical kick start starting device 200 is transmitted to the kicker pinion via the kicker gear 220. In this case, the kicker pinion is meshed with the teeth on the front side of the kicker gear 220 along the transmission main shaft 340. At this time, the orthogonal teeth of the kicker pinion and the orthogonal teeth 241 of the kicker clutch portion 240 are also meshed with each other.

[0081] The complementary orthogonal tooth rows are configured to transmit torque or rotational motion from the kicker pinion to the kicker clutch portion 240 in the starting / driving rotation direction x of the transmission main shaft 340, while in the opposite direction from the kicker clutch portion 240 to the kicker pinion, a freewheel is realized based on the obliquely formed tooth surfaces.

[0082] In this way, a co-rotation of the kick start pedal in the starting / driving rotation direction x after the starting process has been performed is avoided. However, the orthogonal toothing 241 also allows the kick start pedal to be returned to its initial position again in the opposite reverse direction y after the starting process. During normal operation of the motorcycle, i.e. when the internal combustion engine is running, the kicker pinion is not engaged with the kicker clutch part 240 nor with the kicker gear 120, but is axially displaced "rearwards" along the transmission main shaft 340.

[0083] In summary, to start the internal combustion engine, both the electric starter system 100 and the mechanical kick-start starter 200 act on the kicker clutch part 240. In this case, the torque of the electric starter motor 110 can be transmitted frontally, and the torque of the mechanical kick-start starter 200 can be transmitted axially to the kicker clutch part 240. The torque transmission in this case comprises a freewheel in the form of the starter freewheel device 140 or a freewheel in the form of a ratchet connection between the orthogonal toothing 241 of the kicker clutch part 240 and the orthogonal toothing of the kicker pinion. In this way, the electric starter system 100 can be integrated into the mechanical kick-start starter 200 in a particularly space-saving manner and with minimal modifications. In this case, the functionality of the kick-start starter 200 is fully maintained.

[0084] 6 shows a schematic exploded perspective view of an exemplary embodiment of an electric starter set 100a according to the invention with a cover 250 of the kick-start starting device 200 assembled. The electric starter set 100a comprises an electric starter motor 110, a first starter coupling piece 131, a second starter coupling piece 132, an adapter plate 150, a starter transmission 120 and a kicker clutch part 240, which comprises a starter freewheel device 140, which comprises a starter ring gear 123 on the front side. The first starter coupling piece 131 and the second starter coupling piece 132 together with the mounting part 153 of the adapter plate 150 form a starter transmission housing 130, inside which the starter transmission 120 is accommodated. The starter transmission 120 has a starter pinion 121 and a starter gear 122, where the starter gear 122 meshes with a starter ring gear 123 on the front side.

[0085] The starter pinion 121 is configured as a double gear and meshes with a pinion 124 at the opposite shaft end, which is a component of another double gear. A gear 125 arranged on the same shaft further meshes with a starter shaft pinion 112 of the electric starter motor 110. The starter transmission 120 thus transfers the torque available from the starter shaft pinion 112 to the kicker clutch part 240 by means of its starter ring gear 123 via a number of gears and levels, preferably four gears and three levels.

[0086] Preferably, the electric starter motor 110, the starter transmission housing 130, and the starter transmission 120 and the kicker clutch part 240 with the starter freewheel device 140, which are integrated in the starter transmission housing 130, are already pre-assembled together with the adapter plate 150, so that in order to retrofit a motorcycle with a mechanical kick-start starting device 200, it is only necessary to remove the cover 250 of the mechanical kick-start starting device 200 and to mount the adapter plate 150 together with the corresponding pre-assembled components of the electric starter set 100a between the cover 250 and the transmission housing 310.

[0087] As an optional configuration, for mounting purposes, the electric starter set 100a may be provided with an extended mounting means 251a, which compensates for the increased spacing between the cover 250 and the transmission housing 310 due to the adapter plate 150. Also optionally, the electric starter set 100a may additionally have an extended kicker shaft 210, and / or an extended brake shaft, and / or an extended transmission clutch operating lever 350, and / or an extended clutch push rod 360, each as needed and / or selectively to replace the corresponding original components of the motorcycle.

[0088] In summary, the electric starter set 100a can be easily and hassle-freely retrofitted without requiring special expertise or special tools. The changes to be made in the original components are minimal and barely noticeable from the outside, and the functionality of the mechanical kick-start starting device 200 is fully maintained. Preferably, the original kicker clutch part only needs to be replaced by the kicker clutch part 240 with the starter freewheel device 140 and the starter ring gear 123. Depending on the construction, it may also be necessary to replace the kicker shaft 210 and / or the brake shaft and / or the transmission clutch operating lever 350 and / or the clutch pushrod 360. [Explanation of symbols]

[0089] 100 Electric Starter System 100a Electric Starter Set 110 Electric starter motor 112 Starter shaft pinion 120 Starter transmission 121 Starter pinion 122 Starter Gear 123 Starter ring gear 124 Pinion 125 Gears 130 Starter transmission housing 131 First starter connector 132 Second starter connector 140 Starter freewheel device 141 Radial outer race 142 Radial inner race 143 Rolling elements 150 Adapter Plate 151 Notch 152 Containment Area 153 Mounting part 154 Screw 200 Mechanical kick start starting device 210 Kicker shaft 211 Pedal connection 212 Spring holder 220 Kicker Gear 221 Stopper pin 240 Kicker clutch part 241 Orthogonal dentition 250 Cover 251 Mounting means 251a Extended mounting means 300 Transmission 310 Transmission housing 320 Adapter part 330 Transmission Base Plate 340 Transmission main shaft 350 Transmission clutch operating lever 360 clutch push rod x Starting and driving rotation direction y Reverse direction

Claims

1. An electric starter system (100) for a motorcycle with a four-speed transmission having a mechanical kick-start starting device (200), the motorcycle having a transmission main shaft (340) that rotates in a predetermined starting / driving rotational direction (x) when starting the motorcycle and during normal operation of the motorcycle, the kick-start starting device (200) having a kicker pinion and a kicker clutch portion (240), the kicker pinion being , the kicker clutch portion (240) being axially coupled to the transmission main shaft (340), the kicker clutch portion (240) being torque-transmittingly coupled to the transmission main shaft (340), the electric starter system (100) including an electric starter motor (110) having a starter shaft pinion (112) drivable by the electric starter motor (110), a torque of the electric starter motor (110) can be transmitted from the starter shaft pinion (112) to the kicker clutch portion (240) via an intermediate connected starter transmission (120); The electric starter system (100) has an adapter plate (150), The electric starter system (100) for a motorcycle, characterized in that the adapter plate (150) is configured to connect the electric starter motor (110) to a transmission housing (310) of the motorcycle or to attach the kicker clutch portion (240) to a starter freewheel device (140).

2. 2. The electric starter system (100) of claim 1, characterized in that the electric starter motor (110) is arranged substantially parallel to the transmission main shaft (340), and a torque of the electric starter motor (110) can be transmitted to the kicker clutch portion (240) coupled to transmit torque to the transmission main shaft (340) via one or more stages of the intermediately connected starter transmission device (120) provided in the electric starter system (100).

3. 3. The electric starter system (100) according to claim 1 or 2, characterized in that the electric starter system (100) has a starter ring gear (123) coaxially surrounding the kicker clutch portion (240) for torque-transmitting meshing with a starter gear (122) of the starter transmission (120) or for torque-transmitting meshing with the starter shaft pinion (112) of the electric starter motor (110).

4. The electric starter system (100) of claim 3, characterized in that the starter freewheel device (140) is intermediately connected between the electric starter motor (110) and the kicker clutch portion (240), whereby, in the starting / driving rotation direction (x) of the transmission main shaft (340), a torque-transmitting clutch is formed in a direction starting from the electric starter motor (110) toward the kicker clutch portion (240), and a free-running clutch is formed in a direction starting from the kicker clutch portion (240) toward the electric starter motor (110).

5. 5. The electric starter system (100) according to claim 4, characterized in that the starter freewheel device (140) is configured in the form of a sprag freewheel or roller sprag freewheel, which coaxially surrounds the kicker clutch part (240) and which blocks the rotational movement of the transmission main shaft (340), in particular in a reverse direction (y) opposite to the starting and driving rotation direction (x).

6. 6. The electric starter system (100) of claim 5, characterized in that the starter freewheel device (140) configured in the form of a sprag type freewheel or a roller sprag type freewheel has a radially outer race (141) and a radially inner race (142), the radially outer race (141) being connected to the starter ring gear (123) of the electric starter system (100) in a torque transmitting manner, and the radially inner race (142) being connected to the kicker clutch part (240) of the kick start starting device (200) in a torque transmitting manner.

7. An electric starter system (100) as described in any one of claims 1 to 6, characterized in that the adapter plate (150) is arranged between a cover (250) of the kick start starting device (200) and a transmission housing (310) of the motorcycle, and the electric starter motor (110) is attached to the transmission housing (310) of the motorcycle by the adapter plate (150).

8. An electric starter system (100) as described in claim 3, wherein the adapter plate (150) has an accommodating area (152) for accommodating the starter freewheel device (140).

9. An electric starter system (100) as described in claim 3, wherein the adapter plate (150) has an accommodating area (152) for accommodating the starter ring gear (123).

10. 10. The electric starter system (100) according to claim 1, characterized in that the electric starter system (100) has a kicker shaft (210) with a removable spring retainer (212) for receiving a kick start spring, the kicker shaft (210) being configured for torque-transmitting coupling to a kicker gear (220).

11. An electric starter set (100a) for retrofitting a motorcycle having a four-speed transmission with a mechanical kick-start starting device (200), the motorcycle having a transmission main shaft (340) that rotates in a predetermined starting / driving rotation direction (x) when the motorcycle is started and during normal operation of the motorcycle, The electrical starter set (100a) an electric starter motor (110) comprising a starter shaft pinion (112) drivable by said electric starter motor (110); a kicker clutch part (240) with a starter freewheel device (140), the kicker clutch part (240) being configured for torque-transmitting coupling to the transmission main shaft (340), the starter freewheel device (140) being configured for connecting the kicker clutch part (240) with the starter shaft pinion (112); an adapter plate (150) formed for coupling the electric starter motor (110) to a transmission housing (310) of the motorcycle and / or for accommodating the kicker clutch part (240) provided with the starter freewheel device (140),

12. 12. The electric starter set (100a) of claim 11, characterized in that the electric starter set (100a) is preassembled and the adapter plate (150) is coupled to the electric starter motor (110).

13. 12. The electric starter set (100a) according to claim 11, characterized in that the electric starter set (100a) is preassembled and the kicker clutch part (240) with the starter freewheel device (140) is arranged inside a receiving area (152) formed for this purpose in the adapter plate (150).

14. 13. The electric starter set (100a) according to claim 11 or 12, characterized in that the electric starter set (100a) includes a starter gear (122) and a starter ring gear (123), the starter ring gear (123) being arranged to coaxially surround the kicker clutch portion (240) and the starter freewheel device (140), and the starter gear (122), as a component of a starter transmission device (120), can be arranged to connect with the starter shaft pinion (112) of the electric starter motor (110) and mesh with the starter ring gear (123).

15. 13. The electric starter set (100a) of claim 11 or 12, characterized in that the electric starter set (100a) includes a kicker shaft (210) with a removable spring bearing (212), the kicker shaft (210) being configured to couple to a kicker gear (220) provided on the kick start type starting device (200) so as to transmit torque thereto.

16. The electric starter set (100a) according to any one of claims 11 to 13, characterized in that the electric starter set (100a) comprises a kicker shaft (210) and a brake shaft and a transmission clutch operating lever (350) and a clutch push rod (360), respectively, for optionally and selectively replacing corresponding original components of the motorcycle.

17. A motorcycle equipped with the electric starter system (100) according to any one of claims 1 to 10.

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