TECHNICAL FIELD

[0001] The present subject matter relates to a step through saddle type vehicle. More particularly, the present subject matter relates to the fuel pump for a vehicle.

BACKGROUND

[0002] The step through saddle type vehicles are basically one of the most affordable and popular kind of the vehicle among the world’s population. These kinds of vehicles are mostly powered by the two stroke or four stroke engines. Conventionally carburetor type system has been implemented in vehicles for supplying & metering fuel quantity to the engine. With need to enhance performance, power output & efficiency of same engine as well as reduce emissions, fuel injection system has become popular in step through saddle type vehicles. Thus, a fuel management system is implemented in vehicles to control the fuel being supplied to the engine at right time & in right quantity. Often with vehicles being commercialized for use in multiple markets & variety of users, depending on the market needs, vehicle manufacturers often face a challenge of handling variety of fuel supply system for same vehicle with variant of carburetor system vis-a-vis fuel injection system. The fuel management system of the internal combustion engine has to use the combination of fuel tank along with the fuel pump module to deliver fuel in the engine with the help of the fuel injector. The vehicle fuel system is responsible for delivering the right amount of fuel from a fuel tank to the fuel injector, to maintain an appropriate amount of fuel in the engine for a smooth & efficient process of internal combustion.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The detailed description is described with reference to the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.

[0004] Fig.l is a side view of a step through saddle type vehicle as per one embodiment of the present invention.

[0005] Fig.2 is a perspective view of a frame of step through saddle type vehicle. [0006] Fig.3 is a front view of the step through saddle type vehicle as per one embodiment of the present invention.

[0007] Fig. 4 is an exploded view of the fuel pump module vehicle as per one embodiment of the present invention.

[0008] Fig 4a is a vehicle view with longitudinal mid plane axis as per one embodiment of the present invention.

[0009] Fig. 4b is a sectional view of fuel pump module holder as per one embodiment of the present invention

[00010] Fig. 5 is a sectional view of the fuel tank module as per one embodiment of the present invention.

[00011] Fig.5a is a right side view of the fuel tank module as per one embodiment of the present invention.

[00012] Fig. 6 is an exploded view of the fuel tank module as per one embodiment of the present invention.

[00013] Fig. 6a is a cross sectional view of the fuel pump module bracket and fuel pump module holder as per one embodiment of the present invention.

DETAILED DESCRIPTION

[00014] The conventional carburetor fuel systems lack in the several major aspects e.g. poor efficiency in terms of fuel consumption and performance of the power unit. Also, majorly responsible for the emission of harmful gases which are the main cause for polluting the environment.

[00015] In order to address the shortcomings of the conventional carburetor system, an Electronic Fuel Injection System or EFI has been developed as an improvement over the carburetor in order to calibrate and optimize the fuel/air ratio. The electronic fuel injection system or EFI is utilized to better control fuel to air ratios in order to provide better performance, improve emissions and drivability. Moreover, the need of precise fuel supply creates a necessity for introduction of Electronic Fuel Injection (EFI) system in existing carburetor vehicles.

[00016] Generally, the typical electronic fuel injection system comprises a fuel tank, a fuel pump that is operatively coupled to the fuel tank that directs fuel into the engine. Further, as an improvement over the carburetor, the Electronic Fuel Injection system (EFI) utilizes advanced electronic techniques to adjust the air fuel mixture. Hence, as engines moves away from carburetors and towards fuel injection, the conversion of the carburetor to the Electronic Fuel Injection system (EFI) involves different types of electrical and mechanical modifications in the vehicle. In known art the fuel pump module is typically disposed outside the fuel tank and opposite to the throttle body near engine, which can have potentially adverse effects on the performance of the fuel pump module because of the heat dissipation from the engine. From a manufacturer’s point of view, there exist a need to have platform of products which can have a flexibility to be adapted to fuel pump type system with least complexity in change over time, minimum vehicle design changes & low cost to be able to cater to various market requirements. For a compact saddle type vehicle with utility space like floor board space & storage under the seat, the layout of the powertrain becomes complex owing to the significant space constraints. It is a challenge to design such a compact vehicle with a powertrain disposed under the frame backbone structure & oriented in a substantially longitudinal direction. Additionally, there always exists a requirement of making the width of the vehicle as narrow as possible to enable ease of handling & maneuvering in traffic conditions. Such compact layout vehicles constrain the extent of fuel storage capacity which necessitate disposing the systems like fuel pump module outside the fuel storage module. The fuel pump module also needs to meet additional challenges of being isolated from vehicle vibration loads, hot areas as well as be safe from any accidental damage or breakage which can lead to fatal risk to the user. Also there exists a challenge of mounting the pump module away from the wiring harness of the vehicle to eliminate possibility of potential fire accident. By function, the module is disposed between the fuel tank module & the intake passage or the intake port of the engine. However, for minimizing pressure losses as well as reduce back pressure leakages, the hose lengths connecting these modules need to be as short as feasible. Also there lies an inherent problem of drop in pressure owing to idle state of the vehicle leading to poor startability & drivability arising out of a phenomenon called vapour lock which necessitates enabling discharge of excess pressure fuel supply back to the storage module in a stable manner without any side effects. The discharge process needs to be clean to avoid entry of contamination into the pump module which can be detrimental to the performance of the powertrain. As per known art, such pump module is mounted external to the fuel storage module & is attached with suitable attaching member to the frame structure. Such external mounting adds to the poor aesthetics of the vehicle making it look cluttered. Since pump modules are standard across multiple platform of products, the attaching member is typically configured to be adaptable to suit mounting requirement on the frame structure. However, such designs have key drawbacks. They necessitate high geometrical accuracy requirements on the frame in manufacturing making them costly as well as difficulty to manufacture. Also, service of the system will need dismantling of major parts of the vehicle leading to high service time. Additionally, such a design leads to higher assembly time since the modules need to be assembled on the frame structure in the production line & cannot be assembled as a pre-assembly. Also, the quality check of the fuel storage module along with the fuel pump module is not feasible unless the entire system is assembled on vehicle which can lead to undesirable delay in case of non-conformance or variance related defects in production.

[00017] Generally, a fuel pump module is considered to be the precise device for maintaining the flow of appropriate amount of the fuel to engine with the help of fuel injector. Further, there are basically two ways to disposed the fuel pump module that is inside the fuel tank module or outside the fuel tank module. For the vehicle having compact layout, the disposition of the fuel pump module inside the fuel tank module is complex and difficult due to lack of space, also the serviceability and accessibility of the fuel pump module gets restricted because of the compact layout of the fuel tank module. Moreover, vehicle design becomes complex when the fuel pump module is disposed outside the compact fuel tank in the vehicle having compact layout. Also, such disposition results in change in design or change in location of neighboring parts in the complex layout, thereby increasing cost, lead time for change over as well as more variety in parts.

[00018] Fuel pump packaging outside the fuel tank needs lots of changes in the existing layout and it is very complex to package it outside the fuel tank as the interference with the neighboring parts like frame structure, wiring harness etc. occurs, which results in change in design or change in location of neighboring parts in the compact layout of the step through saddle type vehicle. As per known art, the fuel pump module is mounted onto the frame structure of the vehicle which makes it vulnerable to vibrations loads & eventual durability failure. Also prolonged exposure to such vibrations can lead to poor pumping effectiveness of the fuel leading to poor performance of the engine. Further, when the fuel pump is disposed outside the fuel tank and mounted to the frame with a bracket, the ease of maintenance and serviceability of the fuel pump is poor since if there is any damage to the mounting bracket, entire frame must be replaced which is undesirably costly. Therefore, it is a dual challenge to package the fuel pump module in close vicinity of the fuel injector and fuel tank module without adversely affecting layout, shape & space or with minimal changes in the existing layout & at the same time provide a stable & robust structure which can withstand vibration loads as well as avoid potential breakage from accidental damage or fall of vehicle. Additional problems arise in terms of enabling a robust construction for the fuel pump module when one attempts to dispose it outside the fuel tank e.g. if the vehicle is parked for at least two to three days, the fuel present in the hose leaks and the remaining fuel pressurized back to the fuel tank due to negative pressure. Further, during restart of the vehicle, the pressure of the fuel drops in the hose connected between the fuel pump module and the fuel injector that affects the efficiency of engine, since the fuel pump module is mounted away from the engine and fuel tank which increases the length of hose. The sealing function of the module is also critical to achieve good performance. Moreover, for mounting the fuel pump module outside the fuel tank, it is needed to provide a stable structure from which sufficient space can be formed for easy mounting, ease of serviceability and also for easy access to the fuel pump module which can also minimize accidental damage.

[00019] Therefore, there is a need to have an improved mounting of fuel pump module which overcomes all of the above problems and other problems known in the art.

[00020] Hence, it becomes essential to design an improved mounting of the fuel pump module of the step through saddle type vehicle. The present invention provides a solution to the above problems while meeting the requirements of minimum modifications in vehicle from carburetor system to fuel injection system, at low cost with ease of manufacturing etc.

[00021] With the above objectives in view, the present invention relates to the electronically controlled fuel injection or carburetion system, and more particularly to the improved mounting of fuel pump module where the fuel pump module is mounted outside & directly on the fuel tank having low volume with a fuel pump module mounting bracket on one side of the longitudinal mid plane of the step through saddle type vehicle i.e. above engine and below the fuel tank, which ensures the pressurized fuel flow from fuel tank to fuel pump module and fuel pump module to the fuel injector from where it goes to combustion chamber, as the fuel pump module is mounted near the fuel tank and engine, ultimately ensures the shortening of hoses in the step through saddle type vehicle having compact shape and size. The shortening of the fuel hose length helps in overcoming the pressure loss and also, engine performance improved as the time taken for generating the pressurized fuel pump is reduced in the vehicle which was in idle state earlier. Further, mounting of the fuel pump module with the fuel pump mounting bracket on the fuel tank reduces the vibration impact on the fuel pump module, protects the fuel pump module from any fatal conditions. The fuel pump module is disposed in between the fuel tank module and the powerunit (engine) without being in direct contact with the frame thereby isolating the module from any direct vibration loads & providing a stable & robust mounting structure. As per an aspect of the present subject matter, the fuel pump module is disposed at one side of the longitudinal mid plane of the main frame, which can supply the fuel to the fuel supply device through a hose with the minimal changes in the vehicle layout, thereby being cost effective.

[00022] As per one aspect of the present invention, the fuel pump module includes the fuel pump, a fuel pump module holder, an adapter, rubber cushion, metal bush, fasteners, intake port, return port, a high-pressure outlet, a coupler portion at the intake port. Further, as per one embodiment of the present invention, the fuel pump module is surrounded by the air cleaner box at the front side of the vehicle & crankcase and SAI filter in the vehicle rear side. Further, in left hand side and right-hand side of the vehicle, the fuel pump module is surrounded by the hinged cover frame and engine cylinder head which ensures the protection of fuel pump module from the external components like stone, dust, water etc. and also decreases the load impact on the fuel pump module. Additionally, as the fuel pump module is bounded by the hinged cover frame, the ease of accessibility and serviceability of the fuel pump module increases, as the accessibility and serviceability of the fuel pump module can be done by loosening the fasteners and removing the hinged cover frame and also, the aesthetic appearance of the vehicle is restored. Further as per one aspect of the present invention, the fuel pump module is mounted between the fuel tank module and the engine such that the fuel pump and fuel injector is juxtaposed to each other and the axis of the intake port, is almost parallel to the ground plane which ensures the fuel from the fuel tank module flows to the intake port of the fuel pump module by gravity as the intake port is always below the return port. Additionally, as per an embodiment, the front portion of the fuel pump module is at least partially open to atmosphere to receive air flow generating a cooling effect from the atmosphere, ultimately increasing the life of the fuel pump module. As per an aspect of the present subject matter, the fuel pump is disposed on opposite side of the exhaust port & exhaust system of the engine since hot components like muffler etc. lead to detrimental effects on the performance & durability of the fuel pump module. To enable further isolation of vibrations coming onto the pump module, the module mounting structure is configured with an elastic damping element e.g. a rubber grommet along with a at least one-point mounting bracket member which enables isolation of vibrations. As per an embodiment, the pump module mounting is configured with an overflow mechanism in form of a tube which is routed back inside the fuel tank module with its opening configured to the atmosphere inside the storage unit. This enables addressing the vapour pressure lock issue while avoiding contamination of the fuel. The fuel pump module is configured with an intermediate attaching means to cater to the adaptation of the standard profile of the fuel pump module to suit the attaching means on the fuel tank module. This attaching means is so configured to additionally function as a heat insulating member to isolate the heat from the engine from being exposed directly to the fuel pump module. The mounting means of the pump module on the attaching means are configured in a substantially orthogonal disposition to enable ease of access from the lateral & front side of the vehicle for ease of dismantling during service. As per an embodiment of the present subject matter, the fuel tank module is configured with an extension member which serves the dual purpose of enabling mounting of the storage unit to the vehicle & also enables mounting of the pump module. As per an embodiment, the attaching means to mount the pump module is welded to the extension member which ensures the welding heat does not distort or lead to any leakage possibility from the fuel tank module.

[00023] As per one aspect of the present invention, the fuel pump module is disposed on the opposite side of the intake pipe having frame structure in between which ensures the shortening of the high-pressure hose. Further, as per one embodiment of the present subject matter, the high-pressure hose is routed from the fuel pump module to the cap of the injector in front of the frame tube above the front portion of cylinder head which ensures the reduction of the impact of heat in the pressurized fuel and also, overcomes the space constraints in the step through saddle type vehicle and also ensures that the hose length is decreased which ultimately protects the hose from the breakage due to tilting or pinchingFurther, as per one aspect of the present invention, the fuel pump module is mounted closely with respect to the wiring harness which is routed along the main frame which ensures the shortening of the wiring harness and also, the opening of the signal coupler from the main wiring harness to the fuel pump module can be easily routed. Further, as per an embodiment, coupler portion of the fuel pump module is facing the ground substantially vertically downward to avoid water entry into the fuel pump module and ease of assembling of coupler in the production line.

[00024] Further, as per one aspect of the present invention, the fuel pump module attaching means or holder holds an adaptor with the help of fasteners, metal bush and rubber cushion which ensures strengthening of the fuel pump module and the adaptor as well as further enables isolating vibrations. Further, as per one embodiment of present invention, the fuel pump module attaching means or holder is made up of metal or plastic material, thereby ensures the structural stiffness to withstand the loads due to fuel pump and vehicle vibration through fuel tank module. Further, as per one embodiment of the present invention, the adaptor has a projected portion (nipple) to which the hose connector is connected.wherer, hose has two ends where one end is assembled with the hose connector at the fuel pump module and the other end is connected to the fuel injector. Further, the fuel injector has a projected portion (nipple) to which the other end of the hose is connected by means of hose clamps, thereby, ensures the shortening of the hose and also, prevent the leakage of fuel. [00025] As per one aspect of the present invention, the fuel tank module is mounted to the fuel storage module of a step through saddle type vehicle above the engine. Further, as per one aspect of the present invention, the fuel tank module includes the fuel tank inner portion, fuel tank outer portion, an inlet, fuel filter, a bracket for return tube and the fuel pump module mounting attaching means e.g. a bracket. Further, as per an aspect of the present invention, the fuel pump module mounting bracket is disposed in between the fuel pump module holder and the mounting plate and the fuel pump module is mounted to the fuel pump module mounting bracket and mounting plate with the grommet, washer and fasteners which ensures the resilient mounting of fuel pump module on the fuel pump mounting bracket. Further, as per one aspect of the present invention, the fuel pump module holder has at least one mounting hole to confirm with the profile of the mounting holes in fuel pump module mounting bracket. Further, as per one aspect of the present invention, the fuel from the fuel filter is supplied to the intake port of fuel pump module through the fuel hose where all the fuel hose is sealed with the hose clamps, thereby, eliminating the risk of fuel leakage and the serviceability of the fuel filter can be done only by removing the hinged cover frame of the vehicle.

[00026] Further, as per one embodiment of the present invention, the fuel in the fuel tank module is filled with the fuel up to the fuel level A and the left-out portion in the fuel tank module is the vapor space. Further, as per one embodiment of the present invention, the return tube; having two ends; is mounted in the fuel tank module inner portion with the return tube mounted bracket which ensures the rigid mounting of the return tube in the fuel tank inner portion. Further, as per one aspect of present invention, the return tube is having two ends where one end of the return tube is connected to the fuel pump module through the hose return and the other end is routed inside the fuel tank inner portion above the bottom level of inlet and is opened into the vapor space above the fuel level A. This configuration ensures the discharging of the fuel vapors generated inside the fuel pump to the vapor space of the fuel tank module and also the fuel which is pressurized beyond the predetermined value, based on the ECU (Electronic Control Unit), is returned back to the fuel tank module with the return tube. Additionally, this routing of return tube eliminates the fuel entry into the fuel pump module through the return tube which is above the fuel level A during fuel filling, vehicle parking and normal driving conditions and also, as the fuel pump module is mounted near the fuel tank module, hence, the length of the fuel hose and return hose is reduced. This also eliminates the problem of vapour lock which is predominant with in-line fuel pump modules & enables smooth startability of the vehicle.

[00027] Various other features of the invention are described in detail below with reference to the accompanying drawings. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the corresponding reference number. With reference to the accompanying drawings, wherein the same reference numerals will be used to identify the same or similar elements throughout the several views.

[00028] Further “front” and “rear”, and “left” and “right” referred to in the ensuring description of the illustrated embodiment refer to front and rear, and left and right directions as seen in a state of being seated on a seat of the saddle type vehicle. Furthermore, a longitudinal axis refers to a front to rear axis relative to the vehicle, while a lateral axis refers to a side to side, or left to right axis relative to the vehicle. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[00029] Fig. 1 illustrates a left side view of an exemplary two-wheeled step through saddle type vehicle, in accordance with an embodiment of present subject matter. The vehicle (100) has a backbone type frame structure (101), which acts as the skeleton for bearing the loads and is also referred to as backbone frame as (shown in Fig 2). Instrument cluster (119) is mounted on handle bar assembly (126). The handle bar assembly (126) is pivotally disposed through the head tube where it includes brake levers (113). The handle bar assembly (126) is connected to a front wheel (129) by one or more front suspension(s) (130). A front fender (131) is disposed above the front wheel (129) for covering at least a portion of the front wheel (129). A leg shield (112) is provided on the vehicle (100). A fuel tank (103) module having fuel cap (114) is mounted to the main tube (101b) (as shown in Fig. 2) of the mono-tube type frame (101) and it is disposed in the front portion F of a step-through space of the mono-tube type frame (101). The vehicle (100) having lighting means which includes Head lamp (127), Tail lamp (106), Turning indicators includes front side indicators (111) and rear side indicator (102) respectively and daytime running lamp (104). The power unit (125) is mounted to the lower portion of said backbone type frame (101). In an embodiment, the power unit (125) is an IC power unit. The fuel tank module (103) is functionally connected to the power unit (125).

[00030] In an embodiment, cylinder axis (C-C’) inclined to a front of said vehicle (100). A swing arm (134) is swingably connected to the backbone type frame (101). A rear wheel (133) is rotatably supported by the swing arm (134). One or more rear suspension(s) (135) connect the swing arm (134) at an angle, to sustain both the radial and axial forces occurring due to wheel reaction, to the mono-tube type frame (101). A license plate (105) and reflector (116) mounted on a rear fender (128) is disposed above the rear wheel (133). A seat assembly (132a, 132b) is disposed at a rear portion (R) of the step-through space. In an embodiment, the seat assembly (132) includes a rider seat (132a), and a pillion seat (132b). The vehicle (100) is provided with the grab rail (109). Further, the seat assembly (132a, 132b) is positioned above the rear wheel (133). The vehicle is supported by a center stand (120) mounted to the frame assembly. A tool box (110) is provided on the left side of said vehicle (100). A cover member (118) is mounted on down tube (101c) (as shown in Fig. 2). The cover member (118) covers at least a portion of the powerunit (125).

[00031] The powerunit (125) includes an, an air intake system (not shown), an exhaust system (not shown), and a starter system (not shown). The starter system includes an electric starter mechanism or a mechanical starter mechanism. The electrical starter system is powered by an auxiliary power source, for cranking the powerunit. Power generated by powerunit is transferred to the rear wheel (133) through a transmission system (not shown).

[00032] The powerunit (125) comprises a cylinder head (123), a cylinder (124) and a chain cover (121) in order from the front to the rear direction of a power unit assembly (122). The cylinder (124) protrudes in a forward direction from the front-end portion.

[00033] Fig. 2 illustrates a perspective view of the frame which is generally of a convex shape, where main tube (101b) extending rearwardly and downwardly from a head tube (101a) of the mono-tube type frame (101), further a floor board supporting down tube (101c) of the mono-tube backbone type frame (101) extends rearward, along a longitudinal axis (L-L’) of the vehicle (100) from a rear portion of the main tube (101b).

[00034] The powerunit (125) (as shown in Fig. 1) is a four-stroke air-cooled power unit where the center portion of the powerunit is supported to the mono-tube type frame (101) via a front bracket (204), and the rear portion thereof is supported by the rear bracket (202). Further, both front bracket (204) and rear bracket (202) brackets are positioned on the lower portion of the down tube (101c) when viewed from the left or right side of the vehicle (100).

[00035] The cover member (118) disposed above the down tube (101c) using attaching means. The attaching means includes two floor mounting brackets (201) attached to the down tube (101c) of the mono-tube type frame (101) to support the cover member (118).

[00036] Fig. 3 illustrates the front view of the step through saddle type vehicle. As per one embodiment of the present invention, the fuel pump module (301) is surrounded by the air cleaner box (302) at the front direction of the vehicle, crankcase (305) and SAI filter (not shown) in the vehicle rear direction. Further, in left hand side view of the vehicle, the fuel pump module (301) is bounded by the hinged cover frame (118) and cylinder head (123) which ensures the protection of fuel pump module from the external components like stone, dust, water etc. and also decreases the load impact on the fuel pump module, and also protects the fuel pump module from the physical damage. Further, as the fuel pump module (301) is bounded by the hinged cover frame, hence at the time of accident of the vehicle, damaging of the fuel pump module decreases. Additionally, as the fuel pump module (301) is surrounded by the hinged cover frame (118), the ease of accessibility and serviceability of the fuel pump module (301) increases as the accessibility and serviceability of the fuel pump module (301) can be done by removing the hinged cover frame (118) alone and also, the aesthetic appearance of the vehicle is restored. Further as per one embodiment of the present invention, the fuel pump module (301) is mounted between the fuel tank module (103) and the engine (125) such that the fuel pump module (301) and fuel injector (not shown) is juxtaposed to each other and the axis of the intake port (307) of the fuel pump module (301), is substantially parallel to the ground plane which ensures the fuel from the fuel tank module flows to the intake port of the fuel pump module by gravity as the intake port is always below the return port (308). Additionally, the front portion of the fuel pump module is slightly open to atmosphere receive the cooling effect from the atmosphere, ultimately increasing the life of the fuel pump module.

[00037] Further, as per one embodiment of the present invention, the fuel pump module (301) is disposed on the opposite side of the components like intake pipe (not shown), muffler (exhaust port) (408) having frame longitudinal mid plane (A-A’) in between, which ensures that the fuel pump module is mounted away from the electrical components and components generating heat like the muffler etc., which ultimately protects the fuel pump module from the fire and other fatal conditions. Further, as per one embodiment of the present subject matter, the high-pressure hose (306) is routed from the fuel pump module (301) to the cap of the injector (not shown) in front of the frame tube above the front portion of cylinder head (123) which ensures the reduction of the impact of heat in the pressurized fuel, overcomes the space constraints in the step through saddle type vehicle and ensures the shortening of the high-pressure hose which ultimately protects the hose from the breakage due to tilting or pinching.

[00038] Further, as per one embodiment of the present invention, the fuel pump module (301) is mounted closely with respect to the wiring harness (not shown) which is routed along the main frame (101b), ensures the shortening of the wiring harness and also, the profile of the coupler from the main wiring harness to the fuel pump module can be easily routed. Further, coupler portion (309) of the fuel pump module (301) faces the ground vertically downward to avoid water entry into the fuel pump module and ease of assembling of coupler in the production line.

[00039] Fig. 4 is the exploded view of the fuel pump module (301). As per one embodiment of the present invention, the fuel pump module includes, intake port (307), return port (308), fuel pump (401), coupler (309), fuel pump module holder (403), adaptor (404). Further, as per one embodiment of the present invention, the fuel pump module holder (403) holds the fuel pump (401) along with the adaptor (404) with the help of fasteners (407), metal bush (406) and rubber cushion (405) which ensures strengthening of the fuel pump module mounting structure and the adaptor and also, protects the fuel pump module from the heat impact generating from the engine. Further as per one embodiment of the present invention, the fuel pump module holder (403) has a projected portion having threaded profile (409b) which conform with the profile present on the fuel pump (401) and further tightened with the fastener. Further, the fuel pump holder has a cut portion (409a) and concave portion (409c) where the fuel pump with coupler portion and return port are supported rigidly (as shown in fig, 4b). Hence, mounting means ensures the rigid mounting of the fuel pump module on the fuel pump holder. Further, the fuel pump module holder (401) is made up of plastic or metal sheet to ensure the structural stiffness to withstand the loads generated by fuel pump module and the vehicle vibrations through the fuel tank module. Further, as per one embodiment of the present invention, the adaptor (404) has a projected portion (nipple) to which the hose connector (304a) (as shown in fig.3) is connected. Further, hose (306) having two ends where one end is assembled with the hose connector (304a) at the fuel pump module (301) and the other end is connected to the fuel injector (not shown), by means of the hose clamps (304b).

[00040] Fig. 5 is the sectional view of the fuel tank module (103). As per one embodiment of the present invention, the fuel tank module (103) is mounted to the main frame (101b) of a step through saddle type vehicle above the powerunit (engine) (125) (shown in fig. 1). Further, as per one embodiment of the present invention, the fuel tank module (103) includes the fuel tank module inner portion (506), fuel tank module outer portion (502), an inlet (501), fuel filter (503), a bracket (505) for return tube (507) and the fuel pump mounting bracket (504). . Further, as per one embodiment of the present invention, the fuel from the fuel filter (503) is supplied to the intake port (307) of fuel pump module (301), where the fuel pump module (301) is mounted outside the fuel tank module through the fuel pump module mounting bracket (504) which is welded on the flange present on the fuel tank module (103), & fluidically connected through the fuel hose (509) (as shown in fig. 5a) where the fuel hose is sealed with the hose clamps, thereby, eliminating the risk of fuel leakage. As the fuel pump module (301) is mounted to the fuel tank module with the fuel pump module mounting bracket hence the impact of vibration on the fuel pump module will decrease, strengthening the mounting of the fuel pump module and also, decreases the requirement of the geometrical manufacturing requirement is reduced to mount the fuel pump module on the fuel tank module, thereby decreasing the assembly timing, takt timing and less manufacturing cost. Further, in production line testing of the components become easy as the mounting of the fuel pump module on the fuel tank module is a subassembly and can be tested with any standard engine.

[00041] Further, as per one embodiment of the present invention, the fuel in the fuel tank module (103) is filled with the fuel up to the fuel level A and the left-out portion in the fuel tank module is the vapor space (B). Further, as per one embodiment of the present invention, the return tube (507) having two ends, is mounted in the fuel tank inner portion

(506) with the return tube mounting bracket (505), ensures the rigid mounting of the return tube (507) in the fuel tank inner portion (506). Further, as per one embodiment of present invention, the return tube (507) has two ends where one end of the return tube

(507) is connected to the fuel pump module (301) through the return hose (508) (as shown in fig. 5a) . The another end of return rube (507) is routed inside the fuel tank inner portion (506) above the bottom level of inlet (501) and is opened into the vapor space (B) above the fuel level A, which thereby ensures the discharging of the fuel vapors generated inside the fuel pump to the vapor space of the fuel tank module. Additionally, the fuel which is pressurized beyond the predetermined value based on the ECU input is returned back to the fuel tank module through the return tube., this routing of return tube (507) eliminates the fuel entry into the fuel pump module (301) through the return tube (507); which is above the fuel level A; during fuel filling, vehicle parking and normal driving conditions and also, as the fuel pump module is mounted near the fuel tank module, hence, the length of the fuel hose and return hose is reduced

[00042] Fig. 6 is the exploded view of the fuel tank module (103). As per one embodiment of the present invention, the fuel pump module holder (403) has two mounting holes (606) which conforms with the profile of the mounting holes (605) in fuel pump module mounting bracket (504), thereby ensuring the poka yoke (error-proof) assembly. Further, as per one embodiment of the present invention, the mounting plate (604) has a plate (604a) and connecting rods (604b) attached together, wherein the fuel pump module mounting bracket (504) is disposed between the mounting plate (604) & fuel pump module holder (403) whereas grommet (603) & washers (602) for damping are disposed between fuel pump module holder (403) & fuel pump module mounting bracket (504) (as shown in fig. 6a). Further as per one embodiment of the present invention, a portion of the grommet (603) is between fuel pump module holder (403) & fuel pump module mounting bracket (504) and the remaining portion of grommet (603) is between mounting plate (604a) & fuel pump module mounting bracket (504). The mounting holes (606) of the fuel pump module holder (403) are inserted into the connecting rods (604b) of the mounting plate (604) and further tightened by the fasteners (601), thereby, to ensure the resilient mounting of the fuel pump module (301) to the fuel pump module mounting bracket (504) and also reduce the vibration .

[00043] The invention helps in overcoming the problem known in the art & additionally problem of space constraints, minimizing the use of new components, increasing the ease of accessibility and serviceability of the fuel pump module of the vehicle while maintaining the overall weight and width of the vehicle and ultimately makes it cost effective.

[00044] Advantageously, the embodiments of the present invention, describes the potential modifications in the mounting of fuel pump module, where the fuel pump module is surrounded by air cleaner box, hinged cover frame etc. This facilitates the simple and easy mounting of the fuel pump module which efficiently increases the ease of accessibility and serviceability of the fuel pump module in the vehicle.

[00045] Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention.

List of reference symbol:

Fig. 1:

100: Step Through saddle type Vehicle.

126: Handle Bar Assembly 119: Instrument Cluster 127: Head Lamp 111: Front Side Indicator

104: Daytime Running Lamp 112: A leg Shield 131 : A front Fender 129: Front Wheel 130: Front Suspension 113: Brake Lever 103: Fuel Tank module 114: Fuel cap 118: Cover Member 123: Cylinder Head 124: Cylinder 122: Power unit Assembly 125: Power unit

132 (132a, 132b): Seat Assembly

101: Mono tube frame

109: Grab Rail

106: Tail Lamp

105: License Plate

102: Rear Side Indicator

128: Rear Fender

116: Reflector

135: Rear Suspension

133: Rear Wheel

134: Swing Arm

121: Chain Cover 120: Center Stand

110: Tool Box C-C’: Cylinder Axis

Fig. 2:

101: Mono Tube Type Frame

101a: Head Tube

101b: Main Tube

101c: Down tube

201: Floor Mounting Brackets

202: Rear Bracket

204: Front Bracket

Fig. 3

301: Fuel pump module

302: Air Cleaner Box

303: Hinged Cover Frame

305: Crankcase

306: Hose

307 : Intake Port

308: Return Port

309: Coupler

Fig. 4

401: Fuel Pump

402: High Pressure Outlet

403: Fuel Pump Holder 404: Adaptor

405 : Rubber Cushion 406: Metal Bush 407: Fasteners

Fig. 4a

A-A’: Longitudinal Mid Plane Fig. 5 501: Inlet

502: Fuel Tank Outer Portion 503: Fuel Filter

504: Fuel Pump module Mounting Bracket 505: Bracket of Return Tube 506: Fuel Tank Inner Portion 507: Return Tube.

Fig. 5a

508: hose return 509: Fuel Hose

Fig. 6

601: Fasteners 602: Washer 603: Grommet 604: Mounting Plate 604a: Plate

601b: Connecting Rods 605 : Mounting Holes of fuel pump module mounting bracket 606: Mounting Holes of fuel pump module holder.