Motorcycle Electric Starter Integration with Kickstart Clutch
Solution Overview
Problem
Existing electric starter systems for motorcycles with mechanical kick-start devices require extensive modifications to the original components, increasing complexity and altering the motorcycle's appearance, especially when retrofitting older models like Harley-Davidson four-speed Big Twins.
Innovation Solution
An electric starter system that transmits torque from the electric starter motor to the kicker clutch part via an intermediate starter gear, utilizing the existing torque-transmitting connection to the transmission main shaft, minimizing modifications and maintaining the original components' functionality and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an electric starter system is integrated into a motorcycle with a mechanical kickstart device, then starting comfort is improved, but device complexity increases due to extensive modifications of original components
Solution Approach 1:
The electric starter motor and its drive mechanism are nested within the existing kickstart device housing. The starter motor is positioned inside the kickstart device, utilizing the same spatial envelope, while the kickstart device itself remains integrated with the transmission system. This nesting approach allows the electric starter to be added without requiring separate mounting space or extensive structural modifications to the motorcycle frame.
Solution Approach 2:
The kicker clutch part is designed to serve dual functions: it acts as both the engagement mechanism for the mechanical kickstart device and the torque transmission interface for the electric starter motor. The same clutch part that engages the kickstart shaft during manual starting also receives torque from the electric starter motor during electric starting, eliminating the need for separate engagement mechanisms and reducing overall system complexity.
2Ease of operation
If an electric starter system is integrated into a motorcycle with a mechanical kickstart device, then starting comfort is improved, but the motorcycle's appearance is altered
Solution Approach 1:
The electric starter motor is nested within the existing kickstart device housing, which is itself integrated into the motorcycle's engine assembly. This nested arrangement ensures that the electric starter components are concealed within existing structural boundaries, maintaining the motorcycle's original aesthetic lines and contours without adding visible external modifications.
Solution Approach 2:
The electric starter system is merged with the existing kickstart device structure, combining both functions within a single integrated assembly. The housing and mounting structures are shared between the mechanical kickstart and electric starter components, creating a unified appearance that blends seamlessly with the motorcycle's original design rather than appearing as separate add-on elements.
3Device complexity
If torque is transmitted from the electric starter motor directly to the transmission main shaft, then device complexity is reduced, but the existing torque-transmitting connection cannot be utilized
Solution Approach 1:
The kicker clutch part is designed to serve dual functions: it acts as both the engagement mechanism for the mechanical kickstart device and the torque transmission interface for the electric starter motor. The same clutch part that engages the kickstart shaft during manual starting also receives torque from the electric starter motor during electric starting, eliminating the need for separate engagement mechanisms and reducing overall system complexity.
Solution Approach 2:
The kicker clutch part serves as an intermediary component between the electric starter motor and the transmission main shaft. Instead of creating a direct connection, the clutch part mediates the torque transmission, allowing the system to utilize the existing kickstart engagement mechanism while accommodating the electric starter motor's drive requirements. This intermediary approach enables compatibility with the existing transmission architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables a compact and efficient electric starter system integration with minimal visual changes, preserving the motorcycle's original appearance and functionality, while providing improved starting comfort and reduced complexity in installation.
Implementation Method 1
an electric starter motor with a starter shaft pinion which can be driven thereby
Data Source
Figure 1
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Figure 3
AI summary
In the case of an electric starter system (100) for a motorcycle with a mechanical kick-start device (200), in particular for a motorcycle of the Harley-Davidson brand with a four-gear transmission, wherein the motorcycle has a main transmission shaft (340) which rotates in a starting and drive rotational direction (x) in order to start the motorcycle and during the normal operation of the motorcycle, and the kick-start device (200) has a kick-start pinion and a kick-start clutch part (240), wherein the kick-start pinion is configured for axial coupling to the kick-start clutch part (240), and the kick-start clutch part (240) is connected in a torque-transmitting manner to the main transmission shaft (340), and wherein the electric starter system (100) comprises an electric starter motor (110) with a starter shaft pinion (112) which can be driven thereby, a solution is to be provided which makes it possible to improve electric starter systems for motorcycles, in particular makes it possible to carry out the installation or retrofitting thereof in the case of a motorcycle with a kick-start device with relatively few modifications of the original components, in a relatively short time and/or relatively simply and/or rapidly. This is achieved by virtue of the fact that a torque of the electric starter motor (110) can be transmitted, in particular via a starter transmission (120) which is connected in between, from the starter shaft pinion (112), preferably at an end side, to the kick-start clutch part (240).