Abstract:
A repair kit for a motor vehicle friction clutch, for example a motorcycle friction clutch, that is economical, simple to install, and which can extend the life of the original outer clutch hub, and a method for repairing the friction clutch. The kit can include an insert for insertion into the clutch. Additionally the kit can provide for the hardening of gear teeth in the clutch without the use of an insert. Additionally, a method for repairing a motorcycle friction clutch using a motorcycle clutch repair kit.

Description:
CONTINUING APPLICATION DATA 
     This application is a Continuation-In-Part application of International Application No. PCT/US99/00284, which was filed on Jan. 7, 1999, and which claims priority from U.S Provisional Application No. 60/070,824, filed on Jan. 8, 1998. International Application No. PCT/US99/00284 was pending as of the filing date of this application. The United States was an elected state in International Application No. PCT/US99/00284. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a repair device and a method for using the repair device for the clutches used in off-road vehicles such as motorcycles and quads. 
     2. Background Information 
     The clutches used in off-road vehicles such as motorcycles and quads and certain other vehicles, are typically run in oil and are often referred to as “wet clutches.” In other words, the clutch in these vehicles is typically lubricated by oil. The clutch&#39;s function is to engage and/or disengage the power from the engine and the transmission. 
     A common problem with this type of clutch is the occurrence of a “dragging” clutch. A dragging clutch is one that does not disengage properly. This dragging clutch problem can often occur where the friction plates wear grooves in the outer clutch hub due to continuous or continual use of the clutch. Known solutions entail filing or machining the grooves from the surface of the outer clutch hub, which tend to be temporary and limited solutions. Alternatively, the outer clutch hub could be replaced, which tends to be an expensive solution compared to a repair of the friction clutch. 
     OBJECT OF THE INVENTION 
     An object of the present invention is to provide a repair kit for a motor vehicle friction clutch, for example a motorcycle friction clutch, that is economical, simple to install, and which can extend the life of the original outer clutch hub. An additional object of the present invention is to provide a method for the repair of a wet friction clutch using a clutch repair kit. An additional object of the present invention is to provide a method for the repair of a motor vehicle friction clutch which involves hardening the outer clutch hub without the addition of additional inserts. 
     SUMMARY OF THE INVENTION 
     At least one embodiment of the present invention can yield these objects by providing a clutch repair kit for the repair of the friction clutch. Specifically, the kit can include an inset, as described below, for insertion into the clutch. Additionally, the kit can provide a cut-out for use in the clutch. Additionally, in at least one embodiment of the present invention, the-kit can provide for the hardening of gear teeth in the clutch without the use of an insert. Additionally, the invention includes a method of repairing the friction clutch in a motor vehicle such as a motorcycle using an embodiment of an insert. 
     The above discussed embodiments of the present invention will be described further hereinbelow with reference to the accompanying figures. When the word “invention” is used in this specification, the word “invention” includes “inventions,” that is, the plural of “invention.” By stating “invention,” the Applicant does not in any way admit that the present application does not include more than one patentably and non-obviously distinct invention, and maintains that this application may include more than one patentably and non-obviously distinct invention. The Applicant hereby asserts that the disclosure of this application may include more than one invention, and, in the event that there is more than one invention, that these inventions may be patentable and non-obvious one with respect to the other. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     At least one embodiment of the present invention is described herein with reference to the accompanying figures, wherein: 
     FIG. 1 shows an expanded view of the components of a clutch assembly such as a clutch assembly for a motorcycle; 
     FIG. 2 shows a new outer clutch hub; 
     FIG. 3 shows a used outer clutch hub indicating wear; 
     FIG. 4 shows a machined outer clutched hub; 
     FIG. 5 shows an outer clutch hub with inserts installed; 
     FIG. 6 shows an embodiment of an insert for repairing a friction a clutch; 
     FIG. 7 shows a side view of clutch plates with inserts installed; 
     FIG. 8 shows an embodiment of an insert for repair of a clutch; 
     FIG. 9 shows an embodiment of an embodiment of an insert for repair of a clutch; and 
     FIG. 10 shows another view of an embodiment of an insert for repair of a clutch; and 
     FIG. 11 shows another embodiment of an insert for repair of a motor vehicle clutch. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 shows an expanded view of a friction clutch assembly such as a friction clutch for a motorcycle. The friction clutch can have an inner clutch hub  5  and can define an axis about which the inner clutch hub  5  can be disposed. Adjacent the inner clutch hub  5  can be a series of at least one steel plate  7  and at least one friction plate  6 . The at least one friction plate  6  and the at least one steel plate  7  can alternate in series next to the inner clutch hub  5 . Each of the steel plates  7  can have teeth or steel plate teeth  14  disposed inward, or toward the axis of the inner clutch hub. The friction plates  6  can have tabs or projections or friction plate tabs  13  which project outward from the friction plates  6 , or in other words away from the axis of the inner clutch hub. 
     A push rod  2  can be disposed through the inner clutch hub  5  and through the steel plates  7  and friction plates  6 . A locknut  8  can hold the push rod  2  with respect to the inner clutch hub  5 . A pressure plate  9  can be disposed adjacent the series of friction plates  6  and steel plates  7 , opposite the inner clutch hub  5 . Clutch spring bolts  11  and clutch springs  10  can be provided to bias the pressure plate  9 . 
     On the side of the inner clutch hub  5  opposite the series of steel plates  7  and friction plates  6 , can be an outer clutch hub  3 . The outer clutch hub  3 , in essence, can be disposed about the inner clutch hub  5  and the plates  6 ,  7 . A spacer  4  can be disposed about the push rod  2  between the inner clutch hub  5  and the outer clutch hub  3 . An actuating lever  1 , and associated components, can be positioned to actuate the friction clutch. A drive gear  12  can be positioned to engage the friction clutch. 
     When the clutch is installed in the engine, the first component placed in the engine can be the outer clutch hub  3 , which outer clutch hub  3  can be designed with a gear connected, for example riveted, to it. This gear can be driven by the drive gear  12 , which drive gear  12  can be located on the crankshaft of the engine (not shown). The gearing arrangement can make the outer clutch hub  3  turn substantially continuously while the engine is running. The inner clutch hub  5  has, for example splines or teeth, to connect or secure the inner clutch hub  5  to the transmission shaft. The inner clutch hub  5  rotates substantially only while the clutch is engaged. 
     When installing the friction clutch, the outer clutch hub  3 , spacer  4  and inner clutch hub  5  can be slid onto the transmission output shaft and held securely in place with a lock nut. Once the inner  5  and outer  3  clutch hubs are in place, the clutch plates  6 ,  7  can be installed. The friction plates  6  can have friction pads or friction material bonded to both sides of the friction plates, and as discussed above, can have a series of tabs  13 , projecting radially outward to secure the friction plates  6  to the outer clutch hub  3 . The flat steel plates or spacer plates  7 , as discussed above, can have a series of teeth  14  to engage the inner clutch hub  5 . The friction plates  6  and steel plates  7  should be installed in alternating order with one of the friction plates  6  nearest the inner clutch hub  5 . The first plate and last plate are typically always friction plates  6 . 
     The push rod  2  can then be installed by sliding into a hole in the end of a transmission output shaft. The pressure plate  9  can then be placed at the end of the clutch hubs  3 ,  5 . Then, the clutch springs  10  and bolts  11  can be installed, which can tightly press or compress the pressure plate  9  against the clutch plates  6 ,  7 . The assembled clutch can be engaged and disengaged by the movement of the actuating lever  1 , which can be located on the side of the engine. The movement of the actuating lever  1  can be controlled by a clutch lever  30  which can be located on handlebars of the vehicle, and which can be connected to the actuating lever  1  by a clutch cable. The normal operating position for the clutch lever  30  is typically “out” or away from the handlebar when the clutch is engaged, (in other words, when the friction plates that are secured to the outer clutch hub and the steel plates that are secured to the inner clutch hub are pressed tightly together by the clutch springs pushing on the pressure plate which allows the inner clutch hub and the outer clutch hub to turn simultaneously to allow the power from the engine to be transferred to the inner clutch hub which is connected to the transmission by way of a splined output shaft.) Typically, when the clutch lever  30  is pulled “into” the handlebar the clutch is disengaged (when the clutch lever is pulled this can turn the actuating arm by way of a clutch cable which can move the push rod against the pressure plate, the pushing motion continuing until the pressure plate has released substantially all pressure applied to the clutch plate). This can allow the clutch plates  6 ,  7  to separate and can allow the inner clutch hub  5  and the outer clutch hub  3  to turn separately which stops the power from the engine and outer clutch hub  3  from being transmitted to the inner clutch hub  5  which is connected to the transmission by way of the splined output shaft. The engaging and disengaging of the clutch can be done at the discretion of the rider, by pulling or releasing the clutch lever  30 . 
     The clutch is a necessary component of these vehicles and is most commonly used when starting, stopping or shifting gears of the transmission. Due to the substantially continuous use of the clutch, as it is regularly being engaged and disengaged, the friction plate tabs  13  can wear grooves into the outer clutch hub  3  fingers or projections  35 . FIG. 2 schematically illustrates a new clutch hub, and FIG. 3 schematically illustrates a worn clutch hub. When the friction plate tabs  13  become “seated” into grooves that have been worn into the outer clutch hub  3 , this can prevent the clutch plates  6 ,  7  from fully separating when the clutch is disengaged which can cause the clutch to “drag” which can cause difficulty stopping the vehicle and which can also cause difficulty shifting the gears. 
     An embodiment of an insert  19  to be used in repair of the clutch is illustrated in FIG.  6 . The insert  19  can be made of a thin steel sheet and can be made into a specific shape. The shape can be achieved, for example, by stamping, forming, machining or other processes which could provide the desired shape. Lower rails  17  of the insert  19  can be designed to secure the insert  19  to the outer clutch hub  3 . End plates  18  of the insert  19  can be designed to substantially prevent the insert  19  from sliding out of the outer hub  3 . The insert faces or wear faces  15  can substantially prevent the friction plates  6  (and their tabs  13 ) from wearing grooves in the outer hub  3 . As the clutch can run in oil, holes or flow holes  16  can be provided in the insert  19  to prevent oil from building up in the insert  19 . 
     In at least one embodiment of the present invention, a base  25  of the insert  19  can have a length of about 36 mm and a width of about 14 mm. The thickness can be about 1 mm or less. The end plates  18  of the insert  19  can have a width of about 14 mm and a height of about 4.5 mm. The sides or wear faces  15  can have a length of about 36 mm and a height of about 4.5 mm. The lower rails or flanges  17  can have, for example, a length of about 36 mm and a width of about 2 mm. 
     It is also possible, in embodiments of the present invention, that the side flanges or lower rails  17  are not substantially parallel to the base plate  25 . In this case it would be possible for the side walls or wear faces  15  to have a height of about 4.5 mm at one end and a height of about 4 mm at the opposing end. 
     In at least one embodiment of the present invention, there can be about 8 flow holes through the base of the insert to allow the passage of oil through the insert, and the holes can each have a diameter of about 4.5 mm. 
     Other dimensions are possible within the scope of the invention to allow for differing clutch sizes and specifically differing sizes of the outer clutch hub  3 , friction plates  6 , and friction plate tabs  13 . 
     For the insert to be installed, the fingers  35  of the outer clutch hub  3  must be filed or machined to a specific size. To do this, the clutch assembly must be removed from the engine. In the process of filing or machining the hub fingers  35 , usually the grooves in the hub fingers  35  are removed. Once all the hub fingers  35  are properly machined or filed to size, the inserts are ready to be installed (see FIG.  4 ). The inner  5  and outer  3  hubs can be reinstalled on the engine. The clutch plates  6 ,  7  can be assembled in a stack in the order they are to be installed, i.e. friction plate, steel plate, friction plate etc. The tabs  13  on the friction plates  6  should be aligned with one another when stacking the plates  6 ,  7 . The inserts  19  can then be positioned over the friction plate tabs  13 . All friction plate tabs  13  should be installed between the end plates  18  of the insert  19 , if the insert  19  has two end plates  18  (see FIG.  5 ). If the insert  19  only has one end plate  18 , then the end plate  18  should be disposed outside of the friction plate tabs. For convenience while installing the inserts  19 , opposing inserts  19  can be installed first and then a retaining device, for example a rubber band, can be placed about the installed inserts  19  to hold them in position while the remainder of the inserts  19  are installed. When all inserts  19  are installed, the clutch plates  6 ,  7 , with inserts  19 , can be installed in the clutch hubs. If the retaining device (for example a rubber band or elastic band) was used, the retaining device can be removed when the clutch plates  6 ,  7  are, for example, approximately half way or further into position. The remainder of the clutch components can be reinstalled after the clutch plates  6 ,  7  and hubs  3 ,  5  are assembled. 
     FIG. 7 illustrates a side view of embodiments of clutch plates  22 ,  23  with an embodiment of an insert  19  installed on the friction plate tabs  13 . The inserts.  19  can be designed to allow a space  20  between the plates  22 ,  23  and the end plate  24  of the insert. This space  20  can allow space for the clutch plates  22 ,  23  to separate during operation. The friction lining or friction material  21  is also shown on the friction plates  23 . 
     FIG. 8 illustrates another view of a possible insert  19 . In this embodiment, at least one of the end plates or faces  18  has been removed. 
     FIGS. 9 and 10 illustrate another possible clutch insert  19  with a slightly different design. In this insert  19 , only one end face  18  is used, and the wear faces  15  are cut to recede at an angle from the open end. Additionally, the substantially triangular section illustrated in FIGS. 9 and 10 can also be cut away from the insert as shown as an alternative embodiment illustrated in FIG.  11 . The embodiments illustrated in FIGS. 8,  9  and  10  can possibly ease installation of the insert in the clutch because of the open end. 
     In at least one embodiment of the present invention as shown in FIGS. 9 and 10, the base  25  can have a length of about 30 mm and a width of about 14 mm. The end plate  18  can have a width of about 14 mm and a height of about 4 mm. The side walls or wear faces  15  can have a length of about 36 mm at their longest point and about 30 or 31 mm at their shortest point. The cut-away end of the side walls can have a straight taper from their longest to their shortest point or can have a section  40  substantially perpendicular to the flanges or lower rails  17  and then another section  41  that tapers to the shortest point. In such an embodiment, the section  40  perpendicular to the lower rails  17  can be about 2.5 mm and the tapered section  41  can be about 4 mm. The tapered section  41  can be between the base plate  25  and the perpendicular section  40 . The lower rails  17  can be about 38 mm long and about 2 mm wide. 
     In at least one embodiment of the present invention as described above, there can be, for example  5  flow holes  16  through the base plate  25 , and, for example, the flow holes  16  can have a diameter of about 4.5 mm. 
     It is also possible in embodiments of the present invention, that the lower rails  17  are not parallel to the base plate  25  but instead are at a slight angle with respect to the base plate  25 . In this case, for example, the side walls or wear faces  15  can have a height of about 4.5 mm at the end adjacent the end plate  18 , and a height of about 4 mm at the open end. 
     In possible embodiments of the present invention, as shown for example in FIG. 11, it is possible for the base plate  25  to contain an additional substantially triangular cut-away section. The cut-away section can be substantially symmetrical about the center of the insert, and each side of the triangular cut-away section  42  can have a length of about 6 mm. 
     In other alternative embodiments of the present invention, it may be possible to use inserts with alternative arrangements and sizes of oil holes or possibly without the oil holes. 
     In other embodiments of the present invention, it may be possible to repair the clutch without using separate inserts by instead hardening the surfaces of the clutch hub projections  35 . For example the projections could be surface treated or otherwise processed to increase the resistance to scoring of the material. This could provide the function of the inserts without requiring the installation of the additional components. 
     While the description above has generally referred to the repair of wet friction clutches, it is within the scope of the present invention to include inserts, as used above, in the initial assembly of a clutch. This could provide the advantage of a longer wearing clutch with less likelihood for the need of repair or replacement of the clutch. 
     One feature of the present invention can be found in a method for repairing the friction clutch of a motorcycle, said method comprising the steps of: removing the clutch assembly from the engine of the motorcycle; sizing the tabs of the friction plates to the necessary size; installing the clutch hubs in the engine of the motorcycle; assembling the friction plates and steel plates in the proper order; aligning the tabs on the friction plates; positioning the inserts about the friction plate tabs; installing the clutch plates and inserts in the engine; and reinstalling the remainder of the clutch components. 
     An additional feature of the present invention can be found in an insert for repairing a motorcycle friction clutch, said insert comprising: a base; said base having first and second edges disposed opposite each another; said base comprising at least one hole disposed therethrough; a first wall; said first wall being disposed substantially adjacent said first edge of said base; said first wall being disposed substantially transverse to said base; a second wall; said second wall being disposed substantially adjacent said second edge of said base; said second wall being disposed substantially transverse to said base and substantially parallel to said first wall; an end plate; said end plate being disposed substantially transverse to said base; said end plate being disposed between said first wall and said second wall; and said first wall, said second wall and said base plate being disposed and configured to permit said insert to be disposed about tabs of friction plates of a motorcycle friction clutch. 
     Yet another feature of the present invention can be found in the insert comprising: a first flange; said first flange being disposed adjacent said first wall; said first flange being substantially transverse to said first wall; said first flange being disposed to project from said first wall away from said base plate; a second flange; said second flange being disposed adjacent said second wall; said second flange being substantially transverse to said second wall; and said second flange being disposed. to project from said second wall away from said base plate. 
     Examples of clutches and methods of repairing clutches, which may be used in embodiments of the present invention, may be found in the following U.S. Patents which are hereby incorporated by reference herein: U.S. Pat. No. 3,191,735, issued Jun. 29, 1965 to Wavak; U.S. Pat. No. 5,322,148, issued Jun. 21, 1994 to Fernandez; U.S. Pat. No. 3,305,060, issued Feb. 21, 1967 to Zeidler; U.S. Pat. No. 3,757,907, issued Sep. 11, 1973 to Crossman et al.; and U.S. Pat. No. 3,885,291, issued May 27, 1975 to DiChiara. 
     Additional examples of clutches and components thereof, and methods for installing or repairing clutches, may be found in the following U.S. Patents which are hereby incorporated by reference herein: U.S. Pat. No. 5,176,236, issued Jan. 5, 1993 to Ghidorzi et al.; U.S. Pat. No. 5,199,542, issued Apr. 6, 1993 to Flotow; U.S. Pat. No. 5,223,882, issued Jun. 29, 1993 to Beckmann; U.S. Pat. No. 5,224,578, issued Jul. 6, 1993 to Rheinheimer et al.; U.S. Pat. No. 5,270,930, issued Dec. 14, 1993 to Ito et al.; U.S. Pat. No. 5,273,672, issued Dec. 28, 1993 to Dasai et al.; U.S. Pat. No. 5,439,087, issued Aug. 8, 1998 to Umezawa; U.S. Pat. No. 5,456,343, issued Oct. 10, 1995 to Murata et al.; U.S. Pat. No. 5,460,255, issued Oct. 24 ,1995 to Quigley; and U.S. Pat. No. 5,383,823, issued Jan. 24, 1995 to Ward et al. 
     The corresponding U.S. Provisional Application, namely U.S. application Ser. No. 60/070,824, filed on Jan. 8, 1998, having the inventor Norman Stout Jr., from which the present application claims priority, is hereby incorporated by reference as if set forth in its entirety herein. 
     The corresponding International Application, namely International Application No. PCT/US99/00284, filed on Jan. 7, 1999, is hereby incorporated by reference as if set forth in its entirety herein. 
     The components disclosed in the various publications, disclosed or incorporated by reference herein, may be used in the embodiments of the present invention, as well as, equivalents thereof. 
     The appended drawings in their entirety, including all dimensions, proportions and/or shapes in at least one embodiment of the invention, are accurate and to scale and are hereby included by reference into this specification. 
     All, or substantially all, of the components and methods of the various embodiments may be used with at least one embodiment or all of the embodiments, if more than one embodiment is described herein. 
     All of the patents, patent applications and publications recited herein, and in the Declaration attached hereto, are hereby incorporated by reference as if set forth in their entirety herein. 
     The details in the patents, patent applications and publications may be considered to be incorporable, at applicant&#39;s option, into the claims during prosecution as further limitations in the claims to patentably distinguish any amended claims from any applied prior art. 
     Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clause are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. 
     The invention as described hereinabove in the context of the preferred embodiments is not to be taken as limited to all of the provided details thereof, since modifications and variations thereof may be made without departing from the spirit and scope of the invention.