TÜV (Technical Inspection Association) – Rules and Regulations for Motorcycle Modifications. What to consider before modifications, what are the TÜV rules for motorcycles, and what is the best way to proceed
Mirrors:
-Mirrors do not require registration.
-Minimum 60 cm² for first registration until 2003.
-Minimum 68 cm² for first registration from 2003.
-Until 1990, one mirror on the left side is 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 must not exceed 500 mm.
-The handlebars must not pinch fingers (e.g., against the tank).
-Holes for fixing controls are allowed.
-Holes between the clamps for cable routing are allowed.
License Plate Holder:
-License plate holders centered on the vehicle do not require registration.
-Side-mounted license plate holders require registration.
When the vehicle is loaded, a license plate must be at least 300 mm from the road surface at its lower edge, but no more than 1200 mm at its upper edge. It may have a maximum inclination of 30 degrees. Specifically for a side-mounted license plate holder, it must be readable from behind at an angle of 30°.
Wheel Cover:
-Wheel covers (fenders) do not require registration.
-For motorcycles, according to STVZO (Road Traffic Licensing Regulations), there is a requirement for a rear wheel cover of 150mm over the axle center and complete coverage of the tread.
-For motorcycles with EC type approval, no specific wheel cover is prescribed.
-A shortened wheel cover is theoretically possible for non-EC ABE, but ultimately it is up to the inspector's discretion. Generally, rear fenders that extend to the middle of the wheel are accepted.
Caution: The license plate does not count as a cover. The installation regulations for reflectors and tail lights must be observed.
Lights and Signaling System:
Headlights, taillights, and turn signals do not require registration. All headlights and taillights 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 number 11 for front, and 12 for rear-facing components. Yellow headlights (except fog lights) are not permitted in Germany.
Parking Light:
-Does not require registration.
-Required by EC, not by StVZO.
-Also allows 2 according to EC.
-According to EC, symmetrically mounted to the vehicle's longitudinal axis; according to StVZO, only within the headlight.
-According to EC, height 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, placement must correspond to the vehicle's longitudinal axis.
-Dual headlights are generally permissible.
-For 2 headlights, the maximum distance between them is 200mm.
-Placement must be symmetrical to the vehicle's longitudinal axis.
-Headlight height 500 – 1,200mm.
-For high beam, a blue indicator light is required (EC); according to StVZO, indication by switch position is also permissible.
Fog Lights:
-Do not require registration.
-Number according to STVZO: 1, max. 250 mm from the vehicle's longitudinal axis; also permitted on crash bars.
-According to EC, 2 are also permissible, symmetrically mounted to the vehicle's longitudinal axis.
-Maximum height as low beam.
-Fog lights must only function together with the low beam.
-Fog lights must have an ECE test mark.
-Yellow fog lights are permitted.
Turn Signal Indicators:
-Do not require registration.
-Required, according to StVZO from first registration 01.01.1962: 4 pieces.
-Front marking: 1, 1a, 1b, 11.
-Rear marking: 2a, 2b, 12.
-Width according to EC: front 240mm, rear 180mm; according to StVZO: front 340mm, rear 240mm.
-Height: 350 – 1,200mm.
-Turn signals on handlebar ends ("Ochsenaugen" - ox eyes): 560mm apart.
-"Ochsenaugen" from first registration 01.01.1987 onwards are only permitted in conjunction with additional rear turn signals.
-Activation indicator required according to EC, permissible according to StVZO.
Brake Light:
-Does not require registration.
-Required by EC; 2 are also permissible.
-Required by StVZO only from first registration 01.01.1988; number 1.
-Mounting position: centered.
-Height: lower edge min. 250mm (min. 350mm according to StVZO), upper edge max. 1,500mm.
Tail Light:
-Does not require registration.
-Required; number 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.
Reflectors:
-Do not require registration.
-Required, not triangular.
-Height: min. 250mm, max. 900mm.
-If integrated into the taillight, no additional reflector is needed.
Air Filter (Single Air Filter):
-Require registration.
-As a rule, a performance and noise measurement is required.
-There are no reports for these; registration must be done by individual acceptance.
-From first registration 1989, an exhaust gas report is required. This is theoretically possible but practically not feasible due to extremely high costs.
The registration of single filters (K&N or DNA) can be done by individual acceptance. The requirements for this depend on the respective inspection body 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.
-Systems with EC-ABE have an E-number stamp (large "E" with number in square); no papers need to be carried.
-For systems with ABE, this must always be carried.
Custom builds require registration, and typically a performance and noise measurement are required. From first registration 1989, an exhaust gas report is required. This is theoretically possible but practically not feasible due to the high costs.
The registration of exhaust systems without ABE or certificate can be done by individual acceptance. The requirements for this depend on the respective inspection body 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.
Driving Noise Limits:
First registration until 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:
-Modifications always require registration.
-Rear frames should have a parts certificate.
-Custom designs without an official certificate according to §19.2 or §19.3 are generally not registrable.
-Shortening or modifying a frame/subframe may be registered under certain circumstances through individual acceptance (depending on the inspecting 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 national (KBA number) or international (EC or ECE mark) approval.
-When installing original brake components from another vehicle, the inspecting engineer is required. Here, the parts inspection of the original vehicle exists. In this case, registration can be done by individual acceptance; the requirements for this depend on the respective inspection body and can vary greatly in terms of effort and cost.
Tires:
-Modifications require registration.
-If a manufacturer's clearance certificate is available, registration by TÜV is usually straightforward.
For tire conversions for which there is no certificate, registration by individual acceptance is required. The following rules must be observed here:
-The tire size must match the rim size. Generally, tire manufacturers indicate in their technical tables which rim dimensions are required for the tire in question.
-The speed rating 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 up to a maximum of 160 km/h and may also be fitted to vehicles whose registered maximum speed is higher. A label "Max. 160km/h" must be affixed to the speedometer (sticker).
-The free movement of the tires must be ensured. We assume a minimum clearance of 5mm from vehicle components to the side of the tire. Longitudinally, it must be noted that the tire grows at higher speeds. Here we observe a minimum clearance of 10mm.
However, these points do not guarantee that your local TÜV office will register your tires. So it's best to consult with them before mounting.
Side/Main Stand:
-Do not require registration.
-A side stand and/or a main stand must be present.
-It must not be possible to ride off with the stand extended.
Footrests:
-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 at least have a material certificate.
-For original parts, a parts inspection of the original vehicle exists.
In both cases, registration can be done by individual acceptance; the requirements for this depend on the respective inspection body and can vary greatly in terms of effort and cost.
Basically
It is best to discuss with the inspecting engineer before making modifications.
Fortunately, there are many TÜV inspecting engineers who have a great affinity for motorcycles and possess the necessary expertise to evaluate and ultimately approve such conversions. You need such an inspector!
However, there are also inspectors who do not want to take this responsibility and will not make any registrations without a certificate or a clearance certificate. If the vehicle is a 300km/h S1000RR, one can have some understanding for this. Should you encounter such an inspecting engineer, I would recommend aborting and approaching another TÜV office.
