TÜV Rules for Motorcycle Conversion
TÜV – Rules and regulations for motorcycle conversions. What needs to be considered before the conversion, what are the TÜV rules for motorcycles and what is the best way to proceed
Mirrors:
- Mirrors do not require registration
- At least 60 cm² for first registration up to 2003
- At least 68 cm² for first registration from 2003
- Until 1990, one mirror on the left side was sufficient; from then on, two are required.
Seat:
- Seats do not require registration
- The number of seats requires registration
- A double seat must have a minimum length of 600mm
- Up to a length of 650mm, a grab handle must be present
- A single seat must have a minimum length of 300mm
Handlebars:
- Handlebars require registration or must have an ABE (General Operating Permit)
- Handlebars must be tested parts
- Off-road handlebars without a certificate / ABE are not permitted
- The grip height above the seat surface may not exceed 500 mm
- The handlebars must not pinch fingers (e.g., against the tank)
- Drillings for fixing controls are allowed
- Drillings between the clamps for routing cables are allowed
License Plate Holder:
- License plate holders in the center of the vehicle do not require registration
- Side-mounted license plate holders require registration
A license plate must be at least 300 mm from the road surface at its lower edge when the vehicle is loaded, but no more than 1200 mm at its upper edge. It may have a maximum inclination of 30 degrees. Especially with a side license plate holder, it must be ensured that it is legible from behind at an angle of 30°.
Wheel Cover:
- Wheel covers (fenders) do not require registration
- For motorcycles, according to STVZO, a regulation for the rear wheel cover of 150mm above the
axle center and a complete covering of the tread applies
- For motorcycles with EC approval, no specific wheel cover is prescribed
- A shortened wheel cover is theoretically possible for non-EC ABEs, but ultimately it is
a matter of the inspector's interpretation. As a rule, rear fenders that extend to the middle over the wheel are accepted.
Note: The license plate does not count as a cover. The mounting regulations for reflectors and tail lights must be observed.
Lights and Signaling System:
Headlights, tail lights, and turn signals do not require registration. All headlights and tail lights must bear a test mark: "Prüfschlange" (test snake) or E-mark. All turn signals must have a test mark that identifies them as turn signals. This is R50 and the number 11 for the front, or 12 for rear-facing components. Yellow headlights (except fog lights) are not allowed in Germany.
Parking Light:
- does not require registration
- mandatory according to EC, not according to StVZO
- according to EC, 2 are also permitted
- according to EC, mounting symmetrical to the longitudinal center of the vehicle, according to StVZO only in the headlight
- according to EC, at a height of 350mm - 1,200mm, according to StVZO up to 1,500mm
Low Beam / High Beam:
- does not require registration
- at least 1 headlight required
- for one headlight, the mounting must correspond to the longitudinal center of the vehicle
- dual headlights are generally permitted
- for 2 headlights, the maximum distance between them is 200mm
- the mounting must be symmetrical to the longitudinal center of the vehicle
- height of the headlights 500 – 1,200mm
- for high beam, a blue indicator light is required (EC), according to StVZO, display by switch position is also permitted
Fog Lights:
- do not require registration
- number according to STVZO: 1, max. 250 mm from the vehicle's longitudinal center, also permitted on crash bars
- according to EC, 2 are also permitted, symmetrical to the vehicle's longitudinal center
- at a height no higher than the low beam
- fog lights may only function together with the low beam
- fog lights must have an ECE test mark
- yellow fog lights are permitted
Turn Signals:
- do not require registration
- mandatory, according to StVZO from first registration 01.01.1962: 4 pieces
- marking front: 1, 1a, 1b, 11
- marking rear: 2a, 2b, 12
- width according to EC: front 240mm, rear 180mm; according to StVZO: front 340mm, rear
240mm
- height: 350 – 1,200mm
- turn signals at the handlebar ends ("ox eyes") 560mm apart
- ox eyes from first registration 01.01.1987 only permitted in conjunction with additional rear turn signals
- activation indicator required according to EC, permitted according to StVZO
Brake Light:
- does not require registration
- mandatory according to EC, 2 also permitted
- mandatory according to StVZO only from first registration 01.01.1988, quantity 1
- mounting position: centered
- height: lower edge min. 250mm (according to StVZO min. 350mm), upper edge max. 1,500mm
Tail Light:
- does not require registration
- mandatory; quantity 1 or 2
- mounting position: centered
- height min. 250mm, max. 1,500mm
- maximum distance to the end of the vehicle 300mm
License Plate Light:
- does not require registration
- required at the rear
Reflector:
- does not require registration
- mandatory, not triangular
- in height min. 250 mm, max. 900 mm
- if integrated into the tail light, no additional reflector is necessary
Air Filter (Single Air Filter):
- require registration
- usually a performance and noise measurement is required
- there are no certificates for this, registration must be done through individual approval
- from first registration 1989, an exhaust gas certificate is required. This is theoretically possible, but practically not due to the
extremely high costs.
The registration of single filters (K&N or DNA) can be done through individual approval. The requirements for this depend on the respective testing authority and can vary greatly in terms of effort and cost. As a rule, a performance and noise measurement is required. For this, a roadworthy vehicle in an otherwise registrable condition is required.
Exhaust Systems:
- require registration or must have an ABE (General Operating Permit)
- Systems with EC-ABE have an E-number stamping (large "E" with number in a square), no documents need to be carried.
- For systems with ABE, it must always be carried.
Self-made systems require registration, and usually performance and noise measurements are required. From first registration 1989, an exhaust gas certificate is required. This is theoretically possible, but practically not due to the high costs.
The registration of exhaust systems without ABE or certificate can be done through individual approval. The requirements for this depend on the respective testing authority and can vary greatly in terms of effort and cost. For this, a roadworthy vehicle in an otherwise registrable condition is required.
Driving Noise Limit Values:
First Registration up to 13.09.53 90 Phon
20.05.56 87 Phon
31.12.56 84 Phon
12.09.66 82 Phon
30.09.83 84 dB(A)N
30.09.90 82 dB(A)N
30.09.95 82 dB(A)N
from 01.10.95 80 dB(A)N
The stationary noise is only a comparative value and is not subject to any restrictions.
Frame/Subframe:
- Changes always require registration
- Rear frames should have a parts certificate
- Self-made constructions without an official certificate according to §19.2 or §19.3 are usually
not registrable
- Shortening or modifying a frame/subframe can under certain circumstances be registered by
individual approval (depending on the inspection engineer)
Brake System:
- Modifications require registration
- Brake lines require registration or must have an ABE
- Brake discs require registration or must have an ABE
- Brake pads must have a national (KBA number) or an international (EC or ECE—
- marking) approval
- when installing original brake components from another vehicle, the
inspection engineer is required. Here, the parts inspection of the original vehicle exists. In this case, an entry can be made via individual approval, the requirements for this depend on the respective inspection body and can vary greatly in terms of effort and cost.
Tires:
- Changes require registration
- If a manufacturer's clearance certificate is available, registration by the TÜV is usually straightforward.
For tire conversions for which no certificate is available, registration by individual approval is required. The following rules must be observed:
- The tire size must match the rim size. As a rule, tire manufacturers state in their technical tables which rim dimensions are required for the relevant tire.
- The speed index of the tires must be at least 10 km/h higher than the maximum speed stated in the documents.
- An exception applies to M&S tires. These winter tires are approved for a maximum of 160 km/h and may also be fitted to vehicles whose registered maximum speed is higher. A marking, "Max. 160km/h" must be affixed to the speedometer (sticker).
- The free movement of the tires must be ensured. Here we assume a minimum distance of vehicle components laterally to the tire of 5mm. Lengthwise, it must be noted that the tire grows at higher speeds. Here we observe a minimum distance of 10mm.
However, these points do not guarantee that your local TÜV office will register your tires. So it's better to discuss it with the staff before mounting.
Side/Center Stand:
- do not require registration
- a side stand and/or a center stand must be present
- it must not be possible to drive off with an extended stand
Footpegs:
- require registration or must have an ABE
- the number must correspond to the number of seats (2 per seat)
Carrier Systems, Cases, Luggage Racks:
- do not require registration.
- the attachment must not affect registration-relevant or safety-relevant parts
Fairing Parts:
- require registration
- if no parts certificate is available, it is advantageous to have at least a material certificate
- for original parts, there is a parts inspection of the original vehicle
In both cases, an entry can be made by individual approval; the requirements for this depend on the respective inspection body and can vary greatly in terms of effort and cost.
Basically
It's best to talk to the inspection engineer before the conversion.
Fortunately, there are many TÜV inspection engineers who have a great affinity for motorcycles and have the necessary expertise to evaluate such conversions and ultimately approve them. You need such an inspector!
However, there are also inspectors who do not want to take on this responsibility and do not want to make any entries without an expert opinion or a clearance certificate. If the vehicle is an S1000RR capable of 300km/h, one can have a certain understanding for that. Should you encounter such an inspection engineer, I would advise you to stop and consult another TÜV station.