yamaha 450/660/700 road legal conversion - quadtechquadtech.co.uk/msva/yamahasport_2010.pdf ·...

Yamaha 450/660/700 Road Legal Conversion

© www.quadtech.co.uk 2010 1

Yamaha 450/660/700 road legal conversion Indicators must be mounted at least 500mm apart. Front Indicators The front indicators must be mounted through the included bracket – carefully squeeze the wire outer to reduce its diameter, remove the nut from the indicator, slide the mounting bracket up the cable and replace the nut. Mount the bracket off the lower headlight mounting bolt Rear indicators and reflectors Indicators must be mounted at least 500mm apart, and reflectors must be at lest 400mm apart. Mount the rear indicators through the mounting bolts used to affix the rear plastic fender to the frame. On the Raptor 700 mount the rear reflectors on the plastic strengthening ribs – drill a small hole and mount facing rearwards. On 450 / 660 mount the reflectors on the Meccano™ style strapping. Use a length with 4 holes, mount the reflector at one end and the other end hole is held by the bolt that holds the indicators to the rear plastics and frame. (See photos) Fuel cap The fuel cap must protrude a maximum of 20mm from the top of the tank and be perceptibly spherical, 660 cap is too high, build a mound on the top of the tank around the cap from car body filler until the cap is no more than 20mm above the mound. Front Brakes Check alignment of front brake cable to ensure that it does not come into contact with any moving parts when the steering is moved from lock to lock.



Headlights and Sidelights VOSA requirements state that headlights and sidelights must either be centrally mounted, or have dipped and main beam mounted symmetrically on either side of the centre line no more than 20cm apart, OR twin dipped beam lights must be at least 40cm apart and mounted symmetrically. Main beam lights must be on or symmetrical to the centre line of the quad. (on quads less than 130cm wide). Lights must be mounted a minimum of 30cm from the ground. Raptor 660 / 700, move the headlights apart by replacing the mounting bolts with longer bolts and spacers – 3 bolts are required to mount each headlight. Some test centres allow masking of the headlight – see photograph. Please check with your test centre before trying this method. YFZ450 headlights are less than 20 cm apart, separate the 3 pin connectors and carefully, using a jewellers screwdriver, release the male pin attached to the yellow wire on the left connector and the male pin attached to the green wire on the right connector. After reconnecting the plugs, one light now lights as dipped and the other as main beam. (Use electricians tape to insulate the disconnected pins). Drill a small hole (or melt with soldering iron in the bottom / side of the headlight which is now main beam, and carefully insert sidelight LED through bulb hole. Tighten into place with nut, and fix pins to cables. Parking Brake Quads must be fitted with a mechanical parking brake to pass the MSVA test, all Yamaha sports quads are fitted with such. There are 2 types of operating mechanism for the parking brake, the early type, (press button, pull clutch, and move lock mechanism) and the later type (over-centre cam). The first type is acceptable for MSVA, the second type needs modification and must either be moved and the parking brake mechanism re-mounted onto the frame near the rider’s left knee, or replaced with a MSVA compatible parking brake.



Handlebar controls Remove the original handlebar switchgear, mount the new switchgear and tether switch (second security device) onto the handlebars, on 450 / 600 carefully remove the 2 pin connector from the original switchgear and mount it onto the wires coming from a normally closed tether switch. On Raptor 660, mount choke mechanism onto switchgear, line-up choke cable in off position, and using long nose pliers push the end of the choke cable into the cable guide. If the choke cable releases itself and pops out, drill a small hole in the mechanism and mount a small tie-wrap to stop the cable releasing Speedometer Mount the speedometer where it is easily visible, either on the plastic cover for the headstock, or on the top of the radiator cover, follow instructions with speedo for mounting, and mount the sensor on the plastic brake protector (front right) and the magnet on the disk. If the brake deflector is loose, tighten by adding a washer on the bolt. The original handlebar cover can be removed to fit the speedo more easily and the key relocated to the front fender. On Raptor 700 late models with factory fitted speedometer, cut the plastic above the speedometer nad mount the warning lamps as shown in the photograph. Mirrors Mount the mirror brackets onto the quad, replacing the original lever mount brackets with those that contain mirror threads. Later style clutch / parking brake levers will need to use longer bolts or countersink the bracket. Once the mirrors brackets have been fitted, screw the mirrors into the brakets, adjust to required position, and tighten the locknut.



Wiring harness Plug the OEM Yamaha connectors - 3 & 4 pin white on 700 and late 450 - 6 pin (and kill tether into 2 pin) on early 450 and 660 on the new harness into the connector on the original harness where the Yamaha switchgear was originally connected. Connect the fused wire inline with the key switch on 660 and early 700. On 450 and late 700 connect the ring terminal to +ve on the battery. Mount the indicator relay and horn onto the frame Run the harness along the left hand side of the quad to the rear. The short wire (purple, black & blue) connects to the front left indicator The short wire (orange, black & blue) connects to the front right indicator The long wire runs to the rear along the left side of the quad. On the long wire, Orange & black goes to the right indicator, Purple & black to the left rear, and on late 450 and 700, the blue and black connects to the number plate light which should be mounted on the underside of the plastic to the rear of the tail light. 2 x 6 pin connectors join the harness to the switchgear. Speed sensor on Raptor and 450 2009 on connects to 3 pin plug on the top of the gearbox, on other models mount speed sensor on a front hub and replace a disk bolt with a magnetic bolt. If using the gearbox sensor set the “P” screen on the Acewell to P=064 if using the original sprockets. Ensure the harness is securely fixed to the frame with tie-wraps 15 Kw / 20hp power restriction Restrict the power to a maximum of 20hp for the MSVA test, this can be done by several methods, of which we can recommend 3 methods.

1) Remove the top of the thumb throttle and insert a piece of plastic / rubber / wood to allow the throttle to only open half way.

2) put a spacer on the throttle body end of the cable to stop it from opening fully

3) on carburettors open the top of the carburettor, and insert a rubber spacer (garden hose approx 25mm length) to stop the slide opening.

Check with your MSVA centre to see which method they prefer. The quad needs to be taken for a dyno run to prove the power is max 20hp before the MSVA test, and the power chart print from the dyno run needs to be presented at the MSVA test.



QUADTECH SPORTS QUAD ROAD LEGAL CONVERSION KITS UPDATE. PLEASE READ THIS BEFORE FITTING.

• Before starting the conversion ensure that all electrical functions on the quad work correctly

including checking that the charging is working correctly on YFZ450 • Remove the front plastics to allow access to the multipin plugs where the original switchgear is

connected. • Plug the Speedometer or warning lamps (2008�> Raptor 700) into the harness � 9 pin black

plug to 9 pin white plug and 6 pin black plug to 6 pin black plug. • Unplug the original switchgear from both sockets and plug the Quadtech harness into the quad

where the original switchgear was connected. • Switch on the bike and test start, stop, and tail light/dipped/main beam functions • If all the functions work, lay the harness onto the bike.

o Find the fused wire. On Raptor 660 and 700 ->2007 disconnect the ignition key and plug the fused wire inline, then plug the key into the fused wire.

o On all other quads connect the ring terminal to +ve on the battery. • Mount the indicators onto the black anodised indicator mounting brackets � NOTE: remove the

nut and washer and screw them up the cable, it's a tight fit but they will come off. • Indicators with 3 wires are front, indicators with 2 wires are rear.

o Connect the left front indicator to the 3 bullet connectors - purple/blue/black (orange on the indicator goes to purple on the harness)

o Connect the right front indicator to the 3 bullet connectors - orange/blue/black o Connect the left rear indicator to the 2 bullet connectors - purple/black (orange on the

indicator goes to purple on the harness) o Connect the right rear indicator to the 2 bullet connectors - orange/black o Mount the indicator brackets to the quad.

• Mount the new switchgear on the handlebars • Connect the numberplate lamp LEDs (where there is not a white bottom to the tail light) to the

blue and black bullet connectors at the rear of the harness. NOTE the numberplate lamp wire with the black sleeve connects to the blue wire on the harness.

• Speed sensor connection: o Raptor �> 2007 & YFZ450R 2009�> disconnect the 3 pin plug on the wire coming out of

the top of the gearbox, and put the 2 x 3 pin plugs inline. ON THE ACEWELL COMPUTER, in the "P "screen, set the value to 064. Measure the circumference of the rear wheel in mm and enter this into the "C" screen

o All other quads not factory fitted with a speedometer, mount the supplied bolt or black plastic box onto the front hub and replace a bolt with the supplied magnet or superglue supplied flat magnet to the disk. Ensure that the sensor is mounted so that the magnet will pass within 5mm when the wheel turns. ON THE ACEWELL COMPUTER, Measure the circumference of the front wheel in mm and enter this into the "C" screen

• On kits supplied with a speedometer, o On kits supplied with a temperature sensor, cut the radiator hose and put the temperature

sensor hose inline. Jubilee clips may be required, and you may need to tighten the sensor in the holder/ apply ptfe tape if you encounter a water leak

o If there is a yellow wire: Raptor should be connected to the coil, disconnect the trigger wire to the coil and

put the yellow wire inline. YFZ450, cut the spade terminal off the end of the yellow wire and solder the wire to

the trigger wire that goes to the coilpack (normally orange). o Connect the other trailing wires as per the instructions in the ACEWELL box.

Fitting instructions

Ensure Raptor runs and all lights work before starting conversion.

� Remove the radiator grill � Remove the front fairing (disconnect 6 pin multiway connector "connector A") � Remove bolts holding radiator � Lay Quadtech harness onto quad, route long wire down the left hand side of the quad towards the rear.

Disconnect and remove handlebar switchgear and Install new handlebar switchgear onto handlebars - either remove locating pin from switch or drill hole for the locating pin in the handlebar. Install engine stop switch onto Right Handlebar

Plug 3 pin and 4 pin connectors on Quadtech harness (white and grey) into the sockets where the Yamaha handlebar switchgear was previously connected (black and white)

Mount speedometer dashboard onto handlebars,

� either onto headstock bolts (necessary to move key) � onto crossbar using "P-Clips" if using handlebars with a crossbar

� or as per attached picture, by bending mounting bracket to fit onto plastic cover

Optionally install temperature sensor into radiator hose if required, alternatively switch temperature gauge function off in speedometer.

Connect connector A to the grey connector on the Acewell dashboard

Remove LH headlight, refit using longer bolts and spacers - this allows the closest point of the headlights to be at least 400mm apart.

Mount indicators either onto headlight lower mounting bolt or drill a mounting hole in the headlight case near the top (drain hole if applicable must point downwards)

There are 2 cables on the Quadtech Harness that end with 3 bullet connectors.

Find the cable containing purple wire.

� Connect harness Purple wire to Indicator Blue wire � Connect harness Blue wire to Indicator Red wire � Connect harness black wire to Indicator Black wire

Repeat above process with Right Headlight using cable containing orange wire, and connect orange wire to Indicator Blue wire.

Wrap the yellow wire on the Quadtech harness around the spark plug lead or connect to coil trigger wire.

Disconnect the 3 pin plug attached to gearbox sensor from the Raptor harness and connect Quadtech Harness inline using the plug on end of grey wire on the Quadtech Harness - this obtains the speed reading for the speedometer.

At rear of quad remove centre reflector,

� If using polished licenceplate lamp - fit lamp at top of bracket where reflector was previously mounted - ensure that enough space is left below the lamp to mount a numberplate, connect spring loaded wire in lamp to blue wire and fixed wire to Quadtech harness black wire.

� If using black LED licenceplate lamp - drill 4mm hole in lower face of rear fender as far back as possible, in the centre of the quad. Mount the LED through this hole and point towards licenceplate (previously reflector) bracket. Attach Bullet connectors to ends of wire. The wire with a black sleeve must connect to the blue wire on the Quadtech harness and unsleeved to black wire.

Remove the outer bolts holding the rear fender to the frame

� Refit mounting rear indicators onto the bolts. � Connect Left indicator to Purple & Black wires on harness � Connect Right indicator to Orange & Black wires on harness � Connect licenceplate lamp to Blue and Black wires on harness. � Drill 4mm hole in rearward facing plastic moulding under rear fenders. Mount reflectors through these holes, ensure

that they point rearwards.

Disconnect ignition key, connect 2 pin plug (with red and brown wires) on Quadtech harness into Yamaha where key previously plugged. Plug key into 2 pin socket on harness (with red and brown wires)

Test that indicators and hazards work correctly with ignition on and off

Check other funcions with ignition on - horn, sidelights, dipped beam, main beam, starter.

Fit cable ties to secure all wiring - be carefull around the fan to ensure the fan blades cannot touch any of the wires.

Mount mirror brackets and mirrors

Refit Radiator, front fairing and grill.

Configure the speedometer using the speedometer instructions.

� With ignition on, Press both buttons together until the display flashes. � Set the clock � Ensure the "S" screen says 1.0 � Measure the distance travelled with one turn of the rear wheel - assuming standard gearing. If you have different

gearing you need to multiply by the changed gear ratio. � Enter this number into the "C" screen. � Set the fuel gauge to "off" � Take the quad for a test ride, and using GPS / satnav ensure speedometer is calibrated accurately. If the speed is too

low, increment the value in the "C" screen. � If it's too high, decrease the value.

Steering Arm:For Bombardier and Polaris 2WD quads, the sensor must be mounted to the steering arm. To install the sensor, drill a 3/8” hole through the steering arm as shown. The sensor must be positioned so that the magnet passes directly in front of it, and no more than 1/2” away. Make sure there is enough space around the hole for the jam nuts to rotate freely. Once the hole has been drilled, install the sensor with one jam nut to the inside and one to the outside. Do not overtighten the jam nuts - the sensor housing will break. Use a thread locking compound (e.g. loctite) instead. Test the system for operation before using loctite.

ATV SENSOR MOUNTINGYAMAHA | SUZUKI | KAWASAKI | POLARIS 2WD | BOMBARDIER

STEP 1B: MAGNET INSTALLATIONRemove one of the stock rotor bolts and install the magnetic bolt as shown. Do not overtighten the magnetic bolt. The maximum torque for the magnetic bolt is 10 ft-lb.

STEP 2: POSITION AND MOUNT SENSORMetal Rotor Shields:For quads with metal rotor shields, position the sensor there. Drill a 3/8” hole through the rotor shield. To do this, put the rotor back on the axle to mark a drill location on the rotor shield where sensor is to be installed. The magnet should pass directly in front of the sensor and no more than 1/2” away. Remove the rotor and drill the 3/8” hole in the shield. Install the sensor so that one jam nut is to the inside and one to the outside. Do not overtighten the jam nuts. Instead, use thread locking compound (e.g. loctite). It is best to test the cable to make sure it is working before using the Loctite. When the computer registers speed and distance, the cable is working.

STEP 3: CABLE ROUTING AND ATTACHMENTSensor cable should be routed along the same path as the brake cable up to the handlebars. Use cable ties to fasten the cables together for a clean look.

Magnetic bolt

If a magnetic bolt will not be used, epoxy

magnet directly on rotor next to bolt or in a void

Speed sensor installed in rotor shield

Bombardier DS650 sensor location Bombardier Rally sensor location Trail Blazer sensor location

250/300/400 EX | TRX450R | KFX700 | PREDATOR

STEP 1A: MODELS WITH GEARBOX SPEED SENSOR Raptor 660 / 700, YFZ450R unplug the 3 pin plug on the top of the gearbox and connect the harness / speedometer inline to this cable. On the computer “P” screen enter the value P 064

ACE-S type fitting. With the sensor held firmly in the correct position, use an ink pen to mark the drill location on the caliper mount (through the sensor mounting hole). Remove the sensor and drill a 1/8” hole through the caliper mount. Use a sharp drill bit! Attach the sensor to the caliper

mount with the screw provided. This is a self tapping screw - the hole size must be 1/8”. To avoid kinks while bending the cable around the caliper mounting bolt, use a hair dryer to warm the cable; then bend carefully.

Honda ATV Kawasaki KFX700 Polaris Predator / OutlawKawasaki KFX 450R

Quadricycle SVA Guide based on VOSA MSVA Inspection Manual

Contents

Section Examination Issue Date Forward May 2003 Glossary of Terms

May 2003

1. Stands May 2003 2. Mirrors - non-bodied vehicles May 2003 3. Mirrors - bodied vehicles

Annex 1 - Field of view layout and methodology May 2003

4. Speedometer May 2003 5. Audible Warning May 2003 6. Lighting

Annex 1 - Moped positional requirements Annex 2 - 3 Wheel Moped positional requirements Annex 3 - Motorcycle positional requirements Annex 4 - Motorcycle and Side Car positional requirements Annex 5 - Tricycle positional requirements

May 2003

7. Unauthorised Use May 2003 8. Projections - non-bodied vehicles May 2003 9. Projections - bodied vehicles

Annex 1 - Determination of "Floor Line" May 2003

10. Registration Plate Space May 2003 11. Hand Holds May 2003 12. Headlamp Beam Pattern - non-bodied vehicles May 2003 13. Headlamp Aim - bodied vehicles May 2003 14. Design and Construction May 2003 15. Tyres

Annex 1 - Load Indicies Annex 2 - Speed Categories

May 2003

16. Braking Systems May 2003 17. Radio Suppression May 2003 18. Exhaust System and Noise May 2003 19. Exhaust Emissions - petrol May 2003 20. Exhaust Emissions - diesel May 2003 21. Brake Performance May 2003 22. Manufacturers Plate - Goods Vehicles only May 2003

23. Engine Power Restriction Information Plate - Category A & B vehicles only May 2003

24. Defrost and Demist - bodied vehicles May 2003 25. Seat Belts - bodied vehicles

Annex 1 - Anchorage Strength Assessment Annex 2 - Seat belt upper anchorage location

May 2003

26. Glazing - bodied vehicles Annex 1 - Determining a Windscreen May 2003

27. Windscreen Wipers and Washers - bodied vehicles May 2003 28. Masses and Dimensions May 2003

Forward 1. Preface

The purpose of this Manual is to set out the testing procedures and standards for those Vehicle Inspectorate Examiners that carry out the inspection on machines submitted for Motorcycle Single Vehicle Approval (MSVA). Owners should also find the manual useful as it details the inspection to which machines are subjected and the reasons why a Ministers Approval Certificate (MAC) may be refused. This Manual was based on the Regulations in force at the time of going to print, but changes in the law may result in variations to the test requirements.

2. Application

The Motorcycle Single Vehicle Approval Scheme applies to:

Mopeds

4 wheeled vehicle (heavy quadricycles)

� fitted with an internal combustion engine having a cylinder capacity of more than 50cc and/or a maximum design speed of more than 45km/h (28mph),

� not exceeding 400kg (550kg for goods vehicles), and, � if designed to carry goods, a payload of a maximum of

1000kg, � if powered by an electric motor, the maximum

continuous power must not exceed15kW, and � the weight of the batteries must not be included in the

unladen weight.

Heavy quadricycles shall be considered to be motor tricycles and shall fulfil the technical requirements applicable to motor tricycles.

3. Obligatory Ministers Approval Certificate

In order to obtain a licence and be registered for the first time in the UK all the classes of vehicle in section 2 above will need to obtain a Ministers Approval Certificate (MAC)

4. Scope of the Inspection

The design and construction requirements applicable to any particular vehicle are contained in the Motor Cycles (Approval) Regulations 2003 as amended (the Approval Regulations). The inspection procedures within this manual have been developed to assess, as far as is practicable, the ability of the vehicle to comply with the requirements. This manual is not a legal interpretation of the Regulations.

The issue of a Ministers Approval Certificate should not be taken as absolute evidence that the vehicle complies with the Approval Regulations or that the vehicle can legally be used on the road because, for example, the requirements only relate to construction not condition.

7. Layout

Each test is laid out with 3 headings.

Application

This describes to which vehicle class the test applies. There may be more than one vehicle type, for example, bodied and non-

bodied vehicles in the same class. In this case the manual will have a separate test for each type.

Requirements and Procedures

This describes the requirements the vehicle has to meet to pass the examination, and where necessary the methodology (procedure) of carrying out the test. This procedural description will only be used where the testing method is not clear from the requirement description, or specialist equipment is needed to carry out the test. If there are other acceptable comparable standards that can be accepted as an alternative to the standards required in the manual they will be listed in this section under the subheading of Other Acceptable Standards. Documentary evidence will need to be provided by the presenter for these standards to be accepted. The examiner still retains the right to test the vehicle against the SVA requirements if they have any reason to doubt compliance with the indicated standard.

Reasons for Failure (RfF)

This describes the reasons when the vehicle does not meet the requirements.

Definitions

In this manual references are made to various vehicle categories, these are:

Category A – Mopeds. Category B - Motorcycles with a cylinder capacity not exceeding 125cc and a power not exceeding 11kW(15bhp). Category C - Motorcycles with a power not exceeding 25kw (33.5bhp) and a power/mass ratio not exceeding 0.16kW/kg. Category D - Motorcycles other than those in categories B and C. References are also made to vehicle classes which are covered by Schedule 1 of the Regulations. These are

Glossary of Terms

Blunted Edge

An edge not likely to cause injury whatever the circumstances under finger/thumb pressure (contact is not likely to puncture the skin).

Brake control reserve travel

Any brake which when fully applied has a capability for further application by the control lever before reaching the end of its travel.

Brake Efficiency

Maximum total brake force expressed as a percentage of maximum gross weight.

Cab

The part of the bodywork constituting the compartment reserved for driver and passenger, including its doors.

Designated Seating Position

A position where there is a seat designated for normal use while the vehicle is traveling on the road.

Disabled Person’s Belt

A seat belt which has been specially designed or adapted for use by an adult or young person suffering from some physical defect or disability and which is intended for use solely by such a person.

External Surface

The outward facing surface of the vehicle at any height from the floor line up to a height of 2m from the horizontal surface on which the vehicle is standing.

Extreme Outer Edge

In relation to the side of a vehicle, the vertical plane parallel with the longitudinal axis of the vehicle and coinciding with its lateral outer edge, disregard the projection of;

A. distortion of any tyre due to the weight of the vehicle B. connections for tyre pressure gauges C. anti-skid devices mounted on the wheels D. rear view mirrors E. lamps and reflectors F. customs seals and devices for securing and protecting such seals G. special equipment H. in respect of Section 8/9 (Exterior Projections) only; windows, handles, hinges, push buttons and fuel tank filler caps.

Note. In respect of item ‘g’ "Special Equipment" is - a movable platform fitted to a vehicle; the apparatus for moving the platform and any jacks fitted to the vehicle for stabilising it while the vehicle is moving.

Front fog lamp

A front fog lamp is defined as a lamp used to improve the illumination of the road in case of fog, snowfall, rainstorms etc., with a wide flat topped beam which operates by an independent switch (irrespective of the operation of any position or head lamp).

Hand Brake

A brake system operated by a hand control, which is designed to be used as a service brake.

Harness Belt

Means an adult belt which is a harness belt comprising a lap and shoulder straps.

Load/Speed index

Code numbers and letters that, by referring to a chart, show the maximum weight and speed which that tyre is capable of sustaining.

Ignition Switch

A key operated switch normally used to start the engine.

Insecure

A component or its fixing is, due to its design or a construction feature, not completely attached to the vehicle structure or to another associated component as intended.

Lap Belt

A seat belt which passes across the front of the wearer’s pelvic region and which is designed for use by an adult.

Longitudinal Plane

A vertical plane parallel to the longitudinal axis of a vehicle.

Max Power Speed

The speed (in RPM) at which the engine develops its maximum power output. If this is not known, the maximum design speed (in RPM) is required (usually the beginning of the red zone on the rev counter).

Park Brake

A brake system which could be hand or foot operated, which must be capable of being sustained in the on position by purely mechanical means, and which is designed to be used as a parking or emergency brake.

Production Vehicle

A vehicle of a make, model and type mass produced by the vehicle manufacturer.

Rear Cab Bulkhead

The part situated furthermost to the rear of the outer surface of the compartment reserved for the driver and passenger (see Cab)

Rotary Piston Engine

An engine in which the torque is provided by means of one or more rotary pistons and not by any reciprocating pistons and which is deemed to be a four stroke engine.

Side Screen

An item of glazing wholly or partly on either side of the driver’s seat that does not slide or move relative to the vehicle or any of its parts (including glazing) in a manner likely to cause abrasion to any glazing surface.

Sit Astride Seats

Seats designed to be sat on with the riders legs hanging down either side, operating motorcycle type control pedals.

Unladen Weight

The mass of the vehicle ready for use and equipped with;

� additional equipment required solely for normal use � complete electrical equipment including lights supplied

by the manufacturer � instruments and devices required by law � the appropriate amounts of liquids in order to ensure

the proper operation of the vehicle - excluding fuel

Upper Seat Belt Effective Anchorage

The mounting or guide point from which the shoulder belt descends to the buckle.

Windscreen

A transparent screen through which the driver must look, which extends above the ‘Windscreen horizontal plane’, as determined by use of ‘Nigel’.

Windshield

A shield through which the driver does not have to look to gain a view of the road ahead, and which does not extend above the ‘Windscreen horizontal plane’

Section 1 - Stands

N/A

Section 2 - Mirrors - non-bodied vehicles

Application This inspection applies to all non-bodied vehicles. Requirement 5f does not apply to mirrors incorporated in body work (not to be confused with a body), such as farings, that are inclined 45° or greater from the centre line of the vehicle.

Requirements and Procedures. 1. Check the number of rear-view mirrors fitted. Quadricycles - 2

2. Check all mirrors for an acceptable approval mark. An acceptable approval mark is an "E" or "e" approval marking. If a mirror is marked with a European approval mark it does not have to meet the requirements of 3, 4 or 5h/i below. Note. If a mirror is not marked with an acceptable approval mark it may still be acceptable if it meets all the requirements below and

the field of view test as laid out in Section 3 Mirrors – bodied vehicles, annex 1. The machine must be positioned on center line "b" for this check.

3. Check the diameter of the reflecting surface of a circular mirror is; a. not less than 94mm, and b. not more than 150mm.

4. Where mirrors are not circular check their reflecting surface is; a. able to contain a 60mm diameter circle (manufactured before 17/06/2003), b. able to contain a 78mm diameter circle (manufactured after 17/06/2003), c. no larger than 120mm x 200mm.

5. Check all mirrors; a. are securely mounted so they remain in a stable position under normal driving conditions giving a stable view (mirrors are allowed to move with the steering), b. so placed that the driver has a clear view of the road to the rear and side(s) of the vehicle, c. have a convex reflecting surface, d. are fitted or set in such a way that the centre of the reflective surface is at least 280 mm from the centre line of the vehicle, with the handlebars in the "straight ahead" position, e. are able to be adjusted from the driving position, a. that protrude beyond the vehicles outer edge are capable of being "knocked back" under impact, g. knock back pivot is no more than 50mm from where it is fixed to the bodywork, h. outer edges of the mirror reflecting surface are encased in a protective housing, and i. if the edges of the protective housing are contactable by a 100 mm sphere, check the edges have a radius of at least 2.5 mm.

Reasons for Failure 1. The minimum number of mirrors; a. are not fitted, b. (in the case of a moped) are not fitted to the offside. 2. A mirror; a. is not permanently marked with an approval mark. 3. The reflecting surface of a circular mirror is; a. less than 94mm, b. more than 150mm. 4. The reflecting surface of a non circular mirror is; a. not able to contain a 60mm diameter circle, b. not able to contain a 78mm diameter circle, c. greater than 120mm x 200mm. 5. A mirror; a. that is insecure, b. so placed that the driver does not have a clear view of the road to the rear and side(s) of the vehicle, c. that does not have a convex reflecting surface, d. is fitted or set so the centre of the reflecting surface is less than 280 mm from the centre line of the vehicle, e. that can not be adjusted from the driving position, f. and stem (where applicable) does not knock back or forward under impact, g. knock back pivot is more than 50mm from its fixing to the bodywork, h. reflecting surface not encased in a protective housing, i. protective housing where contactable by a 100mm sphere that does not have a radius of at least 2.5mm.

Section 3 - Mirrors – bodied vehicles

N/A

Section 4 - Speedometer

Application

This inspection applies to all vehicles.

Requirements and procedures

A vehicle can be fitted with either a dial or a digital speedometer or both.

1. Check a speedometer is; a) fitted, b) capable of indicating the vehicle speed in miles per hour (mph), c) within the field of view of the driver, d) complete (including operating means), e) secure.

2. (Dial speedometer only) Check the speedometer is; a) graduated at uniform levels not exceeding 20 mph (10 mph in the case of low power mopeds), b) for all speeds, up to the maximum design speed of the vehicle, c) and the graduations begin at either 10 mph or 20 mph.

3. Check the speedometer can be illuminated in such a way as it can be read at all times of the day and night.

4. If the speedometer dial has been recalibrated from kph to mph check the dial face or glass is permanently marked.

Reasons for Failure

1. A speedometer; a) not fitted, b) does not indicate the speed in mph, c) not within the direct field of view of the driver, d) incomplete, e) insecure.

2. A dial speedometer; a) indicates speed at intervals exceeding 20 mph (10 mph in the case of low power mopeds), b) not capable of recording speeds up to the vehicle maximum design speed, c) with gradations that do not begin at either 10 mph or 20 mph.

3. A speedometer not capable of being read at all times of day or night. 4. A recalibrated speedometer with the kph marking not permanently replaced by one stating mph.

Section 5 - Audible Warning (Horn)

Application

This inspection applies to all vehicles.


An audible warning device is usually a horn. A horn is defined as an instrument, not being a bell, gong or siren, capable of giving a continuous, uniform sound, and does not vary perceptibly during operation, intended to give warning of the presence of, or a manoeuvre by a vehicle in a dangerous road traffic situation.

1. Check a horn, or an instrument capable of giving an audible warning; a) is fitted, b) is secure, c) functions, d) is loud enough (compared to a comparable machine) to be

heard by another road user, e) the sound of which is continuous or uniform.

Reasons for Failure

1. A horn; a) missing, b) insecure, c) inoperative, d) which operates but is not loud enough to be heard by another road user, e) which emits a sound that is not continuous or uniform.

Section 6 - Lighting

Application

This inspection applies to all obligatory and optional lamps (where fitted) unless stated otherwise in bold.

Notes for Positional Requirements Positional requirements for mandatory lamps can be found at annex’s 1 to 5. The vehicle must be assessed with the steering in the “straight ahead” position. Single lamps must be fitted upon the centre line of the vehicle. Twin lamps must be fitted symmetrically to the centre line of the vehicle. Twin headlamps may be fitted one above the other. A single front position lamp may be fitted to one side of another lamp e.g. headlamp. If this is the case the lamps must be fitted symmetrically to the centre line of the vehicle. Positional requirement for headlamps located “at front of the vehicle” can be considered met if the light emitted does not disturb the driver directly or indirectly. Positional requirements for lamps located “at rear of the vehicle”, should be judged as the rearmost practicable point. Pedals are defined as devices that may act as a means of propulsion instead of the engine. “From the outermost part of the vehicle” means the extreme outer edge of the bodywork disregarding tyres, mirrors, lamps etc. (but including the mudguard of a wheel fitted outside a sidecar bodywork). Where ANY distance between lamps or between lamps and the outermost part of the vehicle is specified, the measurement is the distance is measured from the closest edge of the illuminating surface(s). Minimum height is measured to the lower edge of the illuminated area, and maximum to the highest, other than in the case of a dipped beam lamp where the minimum height is measured to the apparent trace of the beam cut off.

General notes Lamp/Reflector positional requirements achieved by the external masking of part or all of the illuminated surface is unacceptable. Internal permanent masking is acceptable. Front directional indicator intensity must be assessed with the headlamp switched on to dipped beam. Headlamps should not be compared for brightness, but must emit sufficient light to illuminate the road in front of the vehicle on dipped and main (where applicable) beams. On twin headlamp systems one or both headlamps can be illuminated for dipped or main beam. On some mopeds it is permissible for directional indicators to flash at between 45 to 120 times per minute. This check must be carried out with the engine running and the throttle up to 50% open. Care must be taken when assessing a moped with automatic clutch (twist and go). It is permissible that all front lamps move with the steering angle on vehicles where they are designed to do so.


1. Check the vehicle is not fitted with a lamp or retro reflective material capable of showing; a) a red light to the front, b) a light other than red to the rear except; ? amber light from a directional indicator, ? white light from a reversing lamp, interior lamp (bodied vehicles only) or a registration plate lamp, ? yellow reflected light from a registration plate .

2. Check all obligatory (and optional where fitted) lamps and reflectors for; a) correct minimum number fitted, b) operation/completeness/security/condition, c) position (see note 3 above), d) colour, e) intensity.

3. Check all light switches for; a) presence, b) operation, c) security.

4. Check a front positional lamp tell tale is fitted. A separate tell tale is not required if the instrument panel lighting can only be switched on or off with the positional lamp.

5. Check the main (where applicable)/dipped headlamp switch operates simultaneously all main beam headlamps when switched from dipped to main beam and main to dipped beam. It is permissible for the dipped beam to remain lit at the same time as the main beam. 6. Check the stop lamp (where applicable); a) emits a steady red light when any service brake is applied, b) goes out when the brake is released.

7. Check the directional indicators (where fitted) are capable of flashing constantly at a rate of between 60 to 120 times per minute. It is permissible to run the engine during this check. 8. Check the hazard warning device (where fitted); a) operates with the ignition switched both on and off, b) operates all the indicators either simultaneously or alternately front then rear, c) has a tell tale fitted that is either optical or auditory or both. If optical it may be incorporated with the indicator tell tale lamp. If entirely auditory it must be clearly audible to the driver.

9. Check the rear fog lamp (where fitted); a) is fitted with a tell tale lamp visible to the driver, b) cannot be alight unless one or more of the main beam, dipped beam headlights or the front fog lamps are lit, c) can be switched off independently from the front fog lamp, d) has a minimum distance of 100mm from any stop lamp.

10. Check the front fog lamp (where fitted) can be switched on or off independently from the main or dipped beam lamps. 11. Check the headlamp a) is not of the “gas discharge” type, and b) emits sufficient light on either dipped or main beam to illuminate the road in front of the vehicle.

12. Check all reflectors are of the non-triangular type. Reasons for Failure

1. A lamp or retro reflective material capable of showing; a) a red light to the front, b) a light other than red to the rear unless it is a listed exception.

2. An obligatory (or optional) lamp or reflector; a) incorrect minimum number fitted ,

b) missing/insecure/inoperative/incomplete, c) incorrectly positioned, d) not of the correct colour, e) except in the case of a headlamp, not of a similar brightness when compared to a lamp from a vehicle meeting ECWVTA.

3. Any light switch; a) missing, b) inoperative, c) insecure. 4. A light switch; a) does not operate a front positional lamp tell tale (where applicable).

5. A main (where applicable)/dipped headlamp switch does not operate simultaneously all main beam headlamps when switched from dipped to main beam and main to dipped beam.

6. A stop lamp (where applicable); a) does not emit a steady red light when any service brake is applied, b) remains on when the brake is released.

7. A directional indicator (where fitted) not capable of flashing constantly at a rate of between 60 to 120 times per minute (see note 9 under Requirements and Procedures).

8. A hazard warning device (where fitted); a) that does not operate with the ignition switched both on and off, b) that does not operate all the indicators either simultaneously or alternately front then rear, c) tell tale missing or inoperative.

9. A rear fog lamp (where fitted); a) tell tale lamp missing, inoperative or not visible to the driver (visual only), b) that can be switched on independently from the main beam, dipped beam headlights or the front fog lamp, c) that cannot be switched off independently from the front fog lamp, d) which is positioned within 100mm of a stop lamp.

10. A front fog lamp (where fitted) that cannot be switched on or off independently from the main or dipped beam lamps.

11. Any headlamp a) is of the “gas discharge” type, and b) does not emit sufficient light on either dipped or main beam to illuminate the road in front of the vehicle.

12. A triangular reflector fitted.

Section 6 - Lighting Annex 1 - Lighting requirements for mopeds N/A

Annex 2 - Lighting requirements for three wheel mopeds and light quadricycles N/A

Annex 3 - Lighting requirements for Motorcycles N/A

Annex 4 - Lighting requirements for Motorcycles with Sidecar N/A

Annex 5 - Positional requirements for Tricycles N/A

Annex 6 - Positional requirements for Quadricycles

Obligatory lamps Lamps Colour Number Position Main beam White 1 min At front. Max 200mm between single dipped and/or main beam lamps. Vehicles >1300mm wide

must be fitted with 2 lamps.

Dipped beam White 1 or 2 max At the front of the vehicle. Min height 500mm. Max height 1200mm. Max 200mm from a single main beam headlamp. If 2 dipped beam headlamps are fitted, max 400mm from outermost edge of vehicle. Min 400mm distance between illuminating surfaces of twin lamps if vehicle is <1300mm wide. Vehicles >1300mm wide must be fitted with 2 lamps, min 500mm apart.

Front position White 1 min At front of vehicle. Min height 350mm. Max height 1200mm. Vehicles >1300mm wide must be fitted with 2 position lamps, which must be: Max 400mm from outermost part of vehicle, min 500mm distance between illuminating surfaces. Tell tale compulsory (which may be speedo backlight if backlight comes on with the position lamp).

Rear position Red 1 min At the rear of the vehicle. Min height 250mm. Max height 1500mm. Vehicles >1300mm wide must be fitted with 2 position lamps. Vehicles >1300mm wide with 2 rear wheels, the lamps must have a 600mm distance between illuminating surfaces. Vehicles< 1300mm with 2 rear wheels, the lamps may have a 400mm distance between illuminating surfaces if 2 are fitted.

Front indicator Amber 2 max Min height 350mm. Max height 1500mm. Max 400mm from outermost part of vehicle. Min 500mm distance between illuminating surfaces.

Rear indicator Amber 2 or 4 max As front.

Stop Red 1 min Min height 250mm. Max height 1500mm. Vehicles >1300mm wide must be fitted with 2 stop lamps. Vehicles >1300mm wide with 2 rear wheels, the lamps must have a 600mm distance between illuminating surfaces. Vehicles <1300mm with 2 rear wheels, the lamps may have a 400mm distance between illuminating surfaces if 2 are fitted.

Registration White 1 min Must illuminate registration plate area.

Non-triangular rear reflector

Red 1 min At rear of vehicle. Min height 250mm. Max height 900mm. Vehicles >1000mm wide must be fitted with 2 rear reflectors, which must have a maximum distance of 400mm from the outermost part of the vehicle and a minimum distance of 400mm between internal edges, unless vehicles > 1300mm wide the internal edges must be a minimum of 500mm apart.

Hazard warning

Amber As indicator

As indicators. Tell tale compulsory which may be the same warning lamp as indicators.

Optional lamps

Front fog White/yellow 1 Min height 250mm. Max not above highest point of dipped beam headlamp.

Rear fog Red 1 Min height 250mm. Max height 1000mm. Min 100mm from stop lamp. Tell tale compulsory.

Reversing White 1 Min height 250mm. Max height 1200mm

Non-triangular side reflectors

Amber 1 Min height 300mm. Max height 900mm. Must not be obscured by rider/passenger.

Section 7 - Unauthorized Use

Application

This inspection applies to all vehicles with the exception of mopeds. However, if a device is fitted to a moped it must meet the requirements below.

Requirements and Procedures 1. Check the vehicle is fitted with a system intended to prevent the unauthorised use of the vehicle.

Notes.

� The device may be a mechanical or electrical, or an electronic immobiliser or a combination of these in addition to any key operated switch normally used to start the engine.

� Mechanical devices must lock the steering or transmission.

2. If an immobiliser is fitted check it does not operate on the vehicles braking system. 3. Check the protective device cannot accidentally jam when the vehicle is in motion.

Reasons for Failure

1. Any vehicles not fitted with a device preventing unauthorised use of the vehicle. 2. An immobiliser acting upon the vehicle braking system. 3. The device is likely to jam when the vehicle is in motion.

Section 8 - External Projections – non-bodied vehicles

Application

This inspection applies to all non-bodied two, three and four wheeled vehicles.

The requirements set out below do not apply to the space between the motorcycle and side car in motorcycle combinations. Where mopeds are fitted with non-retractable pedals, compliance with the requirements is optional. Pedals are defined as devices that may act as a means of propulsion instead of the engine. All external projections covered by this examination are considered to meet the requirements if they are made from, or covered with, a material having a hardness of less than 60 Shore A, offering a degree of protection. If an item is modified to meet this requirement, the item must be assessed against known materials, methods of manufacturer and attachment of such materials likely to be used by a manufacturer of mass produced vehicles. The materials and methods used may be acceptable if they are permanent and durable. For example pipe lagging (etc.) would be considered unacceptable.


Specific Requirements

1. Check the upper edge of the windscreen (where fitted); a) has a radius of curvature of at least 2 mm, or b) is covered with an edge protection material having a hardness of less than 60 Shore A.

2. Check the ends of the clutch and brake levers are perceptibly spherical and have a radius of curvature of at least 7 mm. 3. Check the leading edge of the front mudguard has a radius of curvature of at least 2mm. 4. Check that the rear edge of any filler cap located on the upper surface of the fuel tank (which is likely to be struck by the rider in the event of a collision); a) that does not protrude more than 15mm above the surface and is smooth or perceptibly spherical, b) that does protrude more than 15mm above the surface and is not perceptibly spherical must be fitted with a protective device (see example below).

This protective device could be of up to 60 Shore A or a harder material with a smooth rounded finish that does not increase the risk of injury if struck.

5. Check the ignition key(s) has a protective cap.

Note. This requirement does not apply to folding, hidden or removable keys or keys which are flush with the surface.

General Requirements

When using the testing device the machine must be held in a straight line and a vertical position with both wheels touching the ground, the steering being free to move within its normal range.

Move the testing device from the front towards the rear of the vehicle to ascertain if any projection coming into contact with the device either grazes or collides with it (see diagram below).

If the device is able to strike the steering control the control must be rotated to its full lock position and the device must remain in contact with the vehicle (see diagram below).

The test shall be carried out on both sides of the vehicle, but not across the rear.

6. Check any projection deemed to graze the testing device shall, in cases other than a stem; a) have a corner with a radius of curvature of at least 3mm, b) have an edge which is blunted, or, in the case of a stem; c) shall have a diameter of at least 10mm, d) the edges (on the end of the stem) shall have a radius of curvature of at least 2mm.

7. Check any projection deemed to collide with the testing device shall, in the cases other than of a stem; a) the edges and corners of which shall have a radius of curvature of at least 2mm, or, in the case of a stem; b) if the stem has a diameter of less than 20mm, the length of the stem shall not exceed half the diameter, c) if the stem has a diameter of 20mm or more the edges (on the end of the stem) shall have a radius of curvature of at least 2 mm.

8. Other than the above, check for any protruding parts pointing outwards, that are; a) pointed, b) sharp, and are likely to increase the risk or seriousness of body lesions suffered by any person struck or grazed by the vehicle in the event of an accident.

Reasons for Failure

1. The upper edge of the windscreen (where fitted); a) does not have a radius of curvature of at least 2 mm, or b) is not covered with an edge protection material having a hardness of less than 60 Shore A.

2. The ends of the clutch and brake levers are not perceptibly spherical and have a radius of curvature of less than 7 mm. 3. The leading edge of the front mudguard does not have a radius of curvature of at least 2mm. 4. The rear edge of any filler cap located on the upper surface of the fuel tank (which is likely to be struck by the rider in the event of a collision); a) which does not protrude more than 15mm above the surface, is not smooth or perceptibly spherical, b) which does protrude more than 15mm above the surface, is not fitted with a protective device.

5. The ignition key(s) are not fitted with a protective cap. 6. Any projection deemed to graze the testing device which, in the case of a plate; a) does not have a corner with a radius of curvature of at least 3mm, b) does not have an edge which is blunted, or, in the case of a stem; c) does not have a diameter of at least 10mm, d) the edges (on the end of the stem) do not have a radius of curvature of at least 2mm.

7. Any projection deemed to collide with the testing device which, in the case of a plate; a) the edges and corners do not have a radius of curvature of at least 2mm, or, in the case of a stem; b) which has a diameter of less than 20mm, the length of the stem exceeds half the diameter, c) which has a diameter of 20mm or more, the edges (on the end of the stem) do not have a radius of curvature of at least 2 mm.

8. Any protruding part pointing outwards, that is; a) pointed, b) sharp, and are likely to increase the risk or seriousness of body lesions suffered by any person struck or grazed by the vehicle.

Section 9 - External Projections – bodied vehicles N/A

Section 9 - Projections - non-bodied vehicles Annex 1 - Determination of “Floor Line”

Position the vehicle on a level surface.

Place a cone having a 30º half angle (or cone segment) on the ground such that the conical surface is touching the outer surface of the vehicle to establish a “contact point”.

Reposition the cone at various locations depending on variations in vehicle shape/contour around the vehicle to establish a series of “contact points”.

The floor line is the theoretical line connecting the established “contact points”.

Note. Jacking brackets, exhaust tailpipe protrusions from under the body and wheels are not to be taken into account when assessing the floor line and it should be assumed that wheel arches are filled in.

Section 10 - Rear Registration Plate Space

Application

This inspection applies to all vehicles other than Low Power Mopeds that do not require registration.


Note. Dimensions of the space for mounting the registration plate must be checked with the “dummy” standard size registration plate specific to that vehicle.

On most vehicles it will be possible to mount the plate in a number of positions in the space provided. Therefore examiners should only fail a vehicle for this check if the dummy plate clearly cannot meet the requirements in any position. The maximum height requirements apply to the upper edge of the plate, and the minimum height requirements apply to the lower edge. Provision for registration plate mounting may be made directly onto a vehicle body on some partial or full bodied vehicles.

1. Check the mounting for the rear registration plate is; a) located so it is positioned at the most practicable rearmost point, b) large enough to accommodate a number plate of the required size. 2. Check the registration plate can be mounted; a) no more than 1.5m from the ground, and b) no less than 0.2m from the ground or the centre of the rear wheel spindle if lower.

Reasons for Failure

1. The mounting for the rear registration plate is not; a) positioned at the most practicable rearmost point, b) large enough to accommodate a number plate of the required size.

2. The registration plate is clearly mounted; a) more than 1.5m from the ground, b) less than 0.2 m from the ground and below the centre of the rear wheel spindle.

Section 11 - Handholds N/A

Section 12 - Headlamp Pattern - non-bodied vehicles

Application

This examination applies to all obligatory dipped beam headlamps fitted to non-bodied vehicles. The examination must be carried out with the machine in the unladen position. Using the aiming screen.


The beam pattern must be met without the use of masks or beam converters unless they are an integral part of the headlamp as it was approved. Devices or materials applied to the inside of a headlamp which were not present at the time of approval are unacceptable.

1. With the headlamp switched to the “dipped” position check the beam pattern; a) dips to the left (near side “kick up”), or b) shows a “flat” beam pattern (no “kick up”), c) shows an alternative dipped beam pattern provided it does not dazzle, and/or adequately illuminates the road ahead of the vehicle, d) does not dip to the right.

2. Check the headlamp has a method of adjusting; a) vertical aim, b) horizontal aim.

Reasons for Failure

1. A dipped beam headlight pattern; a) does not dip to the left, b) does not show a flat beam pattern, c) shows an alternative dipped beam pattern which dazzles and/or does not adequately illuminates the road ahead of the vehicle, d) dips to the right.

2. Any headlamp that has no method for adjusting; a) vertical aim, b) horizontal aim.

Section 13 - Headlamp Aim – bodied vehicles N/A Section 14 - Design and Construction

Application

This inspection applies to all vehicles, unless specifically referred to in bold text.


Note. This section does not apply to any other area or component covered in other sections of this Manual.

1. Check all aspects of the design and construction of the vehicle such that no danger is caused or is likely to be caused to its driver, passengers or any other road users or pedestrians.

Note. The following checks must take account of vehicles use under all conditions including when the vehicle is carrying

passengers. Consideration must be given to the loadings imposed during acceleration, braking and cornering. Assess the ability of the component to withstand the forces and vibration to which it is likely to be subjected.

2. Check the chassis frame giving particular attention to highly stressed parts of the vehicle, such as frame joints and connections, reaction brackets, assembly components, ( bolts, rivets etc.) and attachment points (especially side cars) for; a) strength, b) inadequate welds, c) design characteristics likely to affect the steering, handling or braking of the vehicle.

3. Check body parts, (including full and part-bodied vehicles), such as fairings, windshields, sidecar bodies, seats, mudguards, chain guards, nose cones, side panels etc., for; a) security, b) strength, c) attachment.

4. Check any subframe and its mounting/attachment for; a) security, b) strength.

5. Check visually any wheel, axle/stub axle/spindle, suspension assembly, steering component, drive train (chain, belt, shaft etc), and its fixing for; a) strength, b) security, c) compatibility with its mounting/securing method, d) fouling other parts of the vehicle.

6. Check any fixing/locking/retaining device for; a) presence, b) security, c) strength.

7. Check all fuel system components (e.g. fuel tank, tap, pump, filters etc) and fuel pipes for; a) leaks, b) security, c) fouling by moving parts of the vehicle; and are not within the d) proximity of a heat source, e) subject to a corrosive environment likely to cause premature failure.

8. Check fuel filler caps for; a) presence, b) security, c) and to ensure that when closed they form a positive seal which does not allow fuel to leak.

9. Check all electrical components and cables for; a) security, b) insulation, and are not positioned in such a way as to; c) cause a fire hazard, d) be chafed by another component, e) be damaged by heat, (and specifically a cable) f) not secured at a maximum of 300mm (12 inches).

Note. Electrical cabling must be routed to prevent damage to the insulation, unless contained in a hollow component secured at a maximum of 300mm (12 inches) intervals.

10. Check, (where applicable) any drivers and passengers doors are; a) capable of being securely latched in the closed position, b) not likely to easily burst open.

11. Check all door handles/controls are easily accessible from the adjacent seated position. 12. Check all aperture covers (including luggage compartments, boot, bonnet etc.) are capable of being secured in the closed position. 13. Check all doors, door apertures or entrance/exit apertures (on vehicles without doors) have blunted edges. 14. Vehicles with motorcycle type steering only. Using the steering turn plate where necessary, turn the steering from lock to lock to check; a) there is no fouling between any components which would interfere with the free movement of the steering, b) the handlebars/grips do not come so close to a fixed part (e.g. fuel tank, fairing, etc.) to impede the operation of the controls, c) control cables are not pulled taut on full lock or are not likely to be trapped or caught in a projection, d) any steering damper fitted is properly secured, and is not likely to affect/ impede the control of the vehicle, e) fairings, leg shields or body parts do not impede the steering, f) any likelihood of fouling between any components under normal operating conditions.

15. Quadricycles and 3 wheeled vehicles with 2 front (car type) steered wheels only. Using the steering turn plates where necessary, turn the steering from lock to lock to check wheels and tyres, transmission/braking components which rotate during vehicle operation and steering components for; a) fouling on another component, b) the likelihood of fouling under normal operating conditions.

Reasons for Failure

1. A design or construction feature or characteristic, is, or is likely to, cause a danger to the vehicle driver passenger or to other road users. 2. The vehicle structure or assembly component; a) is of inadequate strength and likely to fail prematurely, b) has a welded joint of inadequate strength and likely to fail prematurely, c) which is so designed it is likely to affect the steering, handling or braking of the vehicle.

3. An body or body part; a) insecure, b) of inadequate strength and likely to fail prematurely, c) attachment or securing method of inadequate strength and likely to fail prematurely.

4. Any subframe/mounting/attachment bracket; a) insecure, b) of inadequate strength and likely to fail prematurely.

5. Any wheel, axle, stub axle, spindle, suspension unit drive train component and/or its fixing; a) of inadequate strength and likely to fail prematurely, b) insecure, c) incompatible with its mounting/securing arrangement, d) likely to foul other parts of the vehicle.

Note. On some scooters the engine/drive train is mounted on the suspension and certain components may be designed to foul against others. Examiners must take this into consideration when carrying out this check.

6. Any fixing/locking/retaining device; a) missing, b) insecure, c) of inadequate strength and likely to fail prematurely.

7. Any fuel system components; a) leaking, b) insecure, c) fouling moving parts of the vehicle, d) positioned near to a heat source, so a leak will cause a fire hazard, e) subject to a corrosive environment likely to cause premature failure.

8. A fuel filler cap; a) not fitted, b) not positively secured, c) not incorporating an adequate sealing arrangement.

9. Any electrical components or cable; a) insecure, b) conductor material exposed such that operation would result in a potential short circuit, positioned in such a way as to; c) cause a fire hazard, d) be chafed by another component, e) be damaged by heat, and any unprotected cable; f) not secured at a maximum of 300mm (12 inches).

10. A driver or passengers door; a) not capable of being securely latched in the closed position, b) likely to easily burst open.

11. Any door handle/control not easily accessible from the adjacent seated position. 12. Any aperture cover not capable of being securely latched in the closed position. 13. Any door or aperture edge not blunted. 14. Vehicles with motorcycle type steering only. a) any fouling between components that interferes with the free movement of the steering from lock to lock, b) insufficient clearance at either full lock position for the handlebars/grips to be properly grasped or the controls to be properly operated, c) restriction to the handlebars by any cables being pulled taut, becoming trapped or by being caught on a projection, d) a steering damper which is insecure, or is fitted in such a way that the steering action is impaired, e) any fairing, leg shield or body part insecure or likely to impede the steering, f) any likelihood of fouling between any components under normal operating conditions.

15. Quadricycles and 3 wheeled vehicles with 2 front (car type) steered wheels. Any wheel, tyre, transmission/braking component which rotates during vehicle operation, and any steering component; a) fouling on another component, b) likely to foul under normal operating conditions.

Section 15 - Tyres

Application

This inspection applies to all vehicles, unless specifically referred to in bold text. This section does not apply to Low Power Mopeds with the exception of item 3.


Arrangement of motorcycle tyre markings. On a motorcycle tyre showing the markings: 100/80 B 18 53 S:

� 100/80-18 will indicate nominal size � 53 will indicate a load capacity of 206kg - see list in

annex 1 � S will indicate a maximum speed of 180kmh/112mph -

see list in annex 2 � B indicates bias belted. Radial tyres will display an R

and cross ply tyres will display a D or no marking.

There are no requirements for car tyres displaying “VR” or “ZR” to display a load index or speed rating, so documentary evidence may be required from the presenter/manufacturer. See explanatory notes at annex 2.

1. Check that each tyre is moulded so that it displays permanently the following information; a) “E” or “e”, JIS (Japanese) or DOT (American) approval marking b) nominal size, c) load capacity, d) speed capability, e) construction type, e.g. Radial

Note. Motorcycle “retreaded” tyres do not require approval marks.

2. Check each tyre for suitability in the case of; a) having the correct nominal size for the wheel to which it is fitted, b) having the correct load capacity for the maximum permitted weight for the axle to which it is fitted, c) having the correct speed capability for the maximum design speed of the vehicle, d) not being fitted in accordance with the direction of rotation marked on the sidewall (where applicable), Note. Directional tyres must be fitted in accordance with the instructions on the sidewall. The direction of forward rotation is indicated by an arrow, words or both. Some wheel rims are marked with their direction of rotation. e) an incorrect mix of tyre structures such as; (i) a crossply or bias belted tyre fitted on the rear axle and a radial tyre fitted on the front axle, (ii) a crossply tyre fitted on the rear axle and a bias belted tyre fitted on the front axle, f) an incorrect mix of tyre structures cross the same axle (tricycles and quadricycles), g) nominal size as any other tyre fitted on the same axle (where applicable),

Reasons for Failure

1. A tyre not moulded, so as to display permanently the required information markings for; a) approval, b) nominal size, c) load capacity, d) speed capability, e) construction type.

2. a) a tyre not the correct nominal size for the wheel to which it is fitted, b) a tyre with a lower load capacity for the maximum permitted weight for the axle to which it is fitted, c) a tyre with a lower speed capability than the maximum design speed of the vehicle, d) a tyre not fitted in accordance with the direction of rotation marked on the sidewall, e) an incorrect mix of tyre structures on different axles , f) an incorrect mix of tyre structures across the same axle , g) a tyre of different nominal size to any other tyre fitted on the same axle,

Section 15 - Tyres Annex 1 - Tyre Load Indicies

Load Indicator

Single Tyre

2 Tyres

Load Indicator

Single Tyre

2 Tyres

(LI) kg kg (LI) kg kg

0 45 90 51 195 390

1 46.2 92.4 52 200 400

2 47.5 95 53 206 412

3 48.7 97.4 54 212 424

4 50 100 55 218 436

5 51.5 103 56 224 448

6 53 106 57 230 460

7 54.5 109 58 236 472

8 56 112 59 243 486

9 58 116 60 250 500

10 60 120 61 257 514

11 61.5 123 62 265 530

12 63 126 63 272 544

13 65 130 64 280 560

14 67 134 65 290 580

15 69 138 66 300 600

16 71 142 67 307 614

17 73 146 68 315 630

18 75 150 69 325 650

19 77.5 155 70 335 670

20 80 160 71 345 690

21 82.5 165 72 355 710

22 85 170 73 365 730

23 87.5 175 74 375 750

24 90 180 75 387 774

25 92.5 185 76 400 800

26 95 190 77 412 824

27 97.5 195 78 425 850

28 100 200 79 437 874

29 103 206 80 450 900

30 106 212 81 462 924

31 109 218 82 475 950

32 112 224 83 487 974

33 115 230 84 500 1000

34 118 236 85 515 1030

35 121 242 86 530 1060

36 125 250 87 545 1090

37 128 256 88 560 1120

38 132 264 89 580 1160

39 136 272 90 600 1200

40 140 280 91 615 1230

41 145 290 92 630 1260

42 150 300 93 650 1300

43 155 310 94 670 1340

44 160 320 95 690 1380

45 165 330 96 710 1420

46 170 340 97 730 1460

47 175 350 98 750 1500

48 180 360 99 775 1550

49 185 370 100 800 1600

50 190 380 101 825 1650

Note 1 Where a vehicle top speed exceeds 300kph (190 mph) the LI must be reduced to 85% of its original capability.

Section 15 - Tyres Annex 2 - Speed Categories

On radial tyres suitable for higher speeds, the letter ‘R’ in the tyre designation (placed in front of the rim diameter) may be replaced by ‘VR’ or ‘ZR’, e.g. 205/55ZR16.

Tyres marked ‘VR’ are suitable for speeds of at least 130mph. Tyres marked ‘ZR’ are suitable for speeds of at least 149mph.

Tyres displaying the ‘VR’ or ‘ZR’ marking may not always display a Max load capacity, Load index or Speed rating.

If a tyre Max load capacity is not displayed, documentary evidence of its capabilities will be required unless the examiner has prior knowledge the tyre is acceptable.

If a tyre Max load capacity is displayed and is suitable, but there is no speed rating letter other than ‘VR’ or ‘ZR’, documentary evidence of the tyre speed rating is only necessary if the vehicle maximum road speed is in excess of 130mph (in the case of a ‘VR’ tyre) or 149mph (in the case of a ‘ZR’ tyre). (‘VR’ and ‘ZR’ are minimum speed ranges, whereas speed rating letters [V,W,Y,] give the maximum speed capability.)

Table 1 For speeds not exceeding 130mph

Corresponding Speed Speed Category Symbol (km/h) (mp/h)

A1 5 3

A2 10 6

A3 15 9

A4 20 13

A5 25 16

A6 30 19

A7 35 22

A8 40 25

B 50 31

C 60 38

D 65 41

E 70 44

F 80 50

G 90 56

J 100 62

K 110 68

L 120 75

M 130 81

N 140 87

P 150 93

Q 160 99

R 170 106

S 180 112

T 190 118

U 200 124

H 210 130

V 240 149 - see table II

W 270 168 - see table III

Y 300 186 - see table IV

The tables below show the allowance of a reduction in load against speed for those tyres displaying V, W and Y speed category symbols. Z (ZR) marked tyres are suitable for speeds in excess of 149mph (240kph) and a tyre may display a Z marking in place of a W or Y.

A tyre displaying a V speed category symbol with a load capacity of 42 will only be classified to a speed of 130mph at a load of 150kg. However using the table(s) below it is possible for a tyre displaying a V category symbol to be fitted to a vehicle with a declared speed of 143mph as long as the calculated load (machine axle weight plus rider) does not exceed a load of 141kg (150kg ÷ 94%).

Table II

For speeds higher than 130mph but not exceeding 149mph (speed category V)

Maximum Speed Load

(km/h) (mp/h) (%)

215 134 98.5

220 137 97

225 140 95.5

230 143 94

235 146 92.5

240 149 91

Table III

.For speeds higher than149mph but not exceeding 168mph (speed category W)

Maximum Speed Load

(km/h) (mp/h) (%)

240 149 100

250 155 95

260 162 90

270 168 85

Table IV

For speeds higher than 168mph but not exceeding 186mph (speed category Y)

Maximum Speed Load

(km/h) (mp/h) (%)

270 168 100

280 174 95

290 180 90

300 186 85

Section 16 - Brakes

Application

This inspection applies to all vehicles. Where there are requirements for specific vehicles the vehicle type will be shown in bold text. Requirements and Procedures

1. Check that every two wheeled vehicle is equipped with; N/A

2. Check that every three wheeled moped is equipped with either; N/A

3. Check that every tricycle or unbodied quadricycle is equipped with; a) a foot controlled service brake device, that operates on all wheels, and b) a secondary (emergency) brake device (that may be the hand brake), or 2 independent service brakes fitted, one acting on the front axle/one acting on the rear axle, and and a parking brake device, that operates on the wheels of at least one axle.

4. Check the service brake system or systems are capable of being operated from the riding or driving position whilst keeping both hands on the steering control. 5. Check (where applicable) the secondary braking system; a) operates progressively, b) is able to be applied from the driving position while keeping one hand on the steering control.

6. Check (where applicable) the parking brake system; a) is able to be applied from the driving position, b) uses a control that is operated independently from any service brake, c) is able to be held in the “on” position by purely mechanical means.

7. Check all braking systems; a) have an adjustment/compensation ability to compensate for friction material wear (where possible), b) have sufficient reserve travel.

8. Check all braking system components (including discs, drums, back plates, callipers, mounting brackets, linkages, pivots, bushes, fixing cables, levers, pedals, locking devices etc.), are; a) present, b) complete, c) secure, d) by design suitable to adequately carry out the function for which they are fitted, e) made of a material of sufficient strength and/or durability to resist the stresses vibration, corrosion and ageing that it will be subject to in normal use, f) not obstructed in travel (moving components only - check in “on” and “off” positions).

9. Check hydraulic (and where applicable, vacuum) brake pipes and hoses for; a) fouling by moving parts, b) kinking, stretching or twisting, c) adequate securing/ support, d) exposure to excessive heat, e) unsuitable joint fittings.

10. Check hydraulic (and where applicable, vacuum) components for leaks (with or without the brake applied).

Note. Vacuum components must be checked with the engine running.

11. Check hydraulic system reservoirs are so designed and constructed that the level of the reserve fluid can be easily checked.

Note. This does not apply to Low Power Mopeds with a maximum speed of up to 25km/h (16mph).

12. Assess the capability of the brake friction surfaces, without dismantling, to dissipate energy sufficiently to maintain the brake performance under all conditions, including long descents, without the occurrence of “brake fade”.

Note. This assessment must take account of the vehicles weight, weight distribution and speed capacity.

13. If the vehicle is fitted with an anti-lock (ABS) braking system, check a system warning light is; a) fitted, b) visible from the driving position, c) operational.

Reasons for Failure

1. Any two wheeled vehicle not equipped with; a) one independent braking device acting on the front wheel, b) one independent braking device acting on the rear wheel.

2. Any three wheeled moped not equipped with; a) two independent service braking devices, which together actuate the brakes on all the wheels, or b) a service brake that operates on all wheels, c) a secondary braking device, and in both cases d) a parking brake device.

3. Any tricycle or quadricycle not equipped with; a) a foot controlled service brake device, that operates on all wheels, b) a secondary brake device, or 2 independent controls, one acting on the front axle and one on the rear axle, and a parking brake device which operates on the wheels of at least one axle.

4. A service brake system not capable of being operated from the riding or driving position whilst keeping both hands on the steering control.

5. A secondary brake system; a) that does not operate progressively, b) that is unable to be applied from the driving position while keeping one hand on the steering control.

6. A parking brake system; a) that is unable to be applied from the driving position, b) that uses a control not operated independently from any service brake, c) unable to be held in the “on” position by purely mechanical means.

7. Any braking system that does not; a) have an adjustment/compensation ability to compensate for friction material wear, b) have sufficient reserve travel.

8. Any braking system component; a) missing, b) incomplete, c) insecure, d) by design unsuitable to adequately carry out the function for which it is fitted, e) of inadequate strength and likely to fail prematurely, f) not made of material sufficiently durable and likely to fail prematurely, g) obstructed in its travel.

9. Any hydraulic and (where applicable) vacuum brake pipe or hose; a) fouled by moving parts, b) kinked, stretched or twisted, c) inadequate secured or supported, d) exposed to excessive heat, e) with unsuitable joint fittings.

10. Any hydraulic and (where applicable) vacuum components, a) leaking, b) situated in a corrosive environment and likely to fail prematurely.

11. Any hydraulic system reservoir with no provision for the reserve fluid to be easily checked. 12. The brake friction surfaces have insufficient capacity to dissipate heat and prevent fade. 13. An anti-lock (ABS) braking system warning lamp; a) missing, b) not visible from the driving position, c) inoperative.

Section 17 - Radio Suppression

Application

All vehicles fitted with a spark ignition engine.


1. Visually check the HT ignition system is fitted with radio interference suppression.

Reason for Failure

1. The HT ignition system is not fitted with radio interference suppression equipment.

Section 18 - Exhaust System / Noise

Application

This examination applies to all vehicles (other than electrically powered vehicles) unless specifically referred to in bold text.


1. Check the exhaust system; a) is complete, b) is fitted with a silencer, c) is secured to the vehicle, d) mountings are of adequate strength to support the weight of the system

Noise test.

Position the vehicle on an unobstructed open test site (concrete or asphalt) which covers a rectangular area the sides of which are at least 3 metres from the vehicle sides, front and rear.

Ensure the engine is at operating temperature. Note. This check should be carried out after the emissions test.

Using a sound level meter of “Type 1” as defined in (BSEN 5969 or IEC651) to the manufacturers instructions, carry out a static noise test.

Using the alignment tool, place the microphone

� at the height of the exhaust outlet, or a height of 200mm, whichever is the higher

� at an angle of 45° to the exhaust outlet in the direction which gives the greatest possible distance between it and the outline of the motorcycle (handlebars excluded), or body contour of a bodied vehicle

� at a distance of 500mm from the exhaust outlet

If the exhaust system has more than one outlet at centres less than 300mm apart, or more than one outlet from a common silencer, the microphone must be faced towards the outlet which is nearest the motorcycle (handlebars excluded), or body contour if bodied vehicle or the highest point above the ground. If the centres of the outlets are more than 300mm apart, separate measurements must be taken for each of them, the highest figure recorded being taken as the test value.

Run the engine at a constant speed of ;

� ¾ of its maximum power speed if that is less than or equal to 5000rpm or

� ½ of its maximum power speed if that is more than 5000rpm

3. Check the level of sound emitted for mopeds, motorcycles and light quadricycles is not more than; a) 91dbA with an engine capacity of less than 80cc, b) 94dbA with an engine capacity of between 80cc to 175cc, c) 99dbA with an engine capacity of above 176cc, for all tricycles and quadricycles a) 99dbA .

Reasons for Failure

1. Any exhaust system; a) incomplete, b) not fitted with a silencer, c) mounting or component insecure, d) mounting of inadequate strength to support the system.

Section 19 - Exhaust Emissions (spark ignition)

Application

This examination applies to all vehicles fitted with a spark ignition engine except;.

� vehicles fitted with rotary engines, � amateur built vehicles, rebuilt vehicles, vehicles

manufactured using the parts of a registered vehicle fitted with engines manufacturerd before 1 January 1993,

� mopeds (including 3 wheeled mopeds and light quadricycles), which are subject to a visual test only.

Where there are requirements for specific vehicles the vehicle type will be shown in bold text. There is no requirement to test alternative or dual fuelled vehicles other than on petrol emissions. Requirements and Procedures

Emission levels Vehicle and/or engine type CO% at idle Mopeds, 3 wheel mopeds and light quadricycles. Any vehicle fitted rotary engine.

Visual check only

Motorcycles, tricycles and heavy quadricycles 4.5%

The exhaust emissions must be checked visually and (where applicable) using an approved and calibrated exhaust gas analyser. Prior to conducting the test, check

� the choke/excess fuel device is not operating � there is sufficient oil in the engine � where possible/applicable the camshaft drive belt for

maladjustment, damage or contamination � the engine is at normal working temperature

1. All vehicles. Run the engine at around half the maximum engine speed for 20 seconds to ensure the engine is purged. Allow the engine to return to idle and assess; a) the idle speed, b) the smoke emitted from the tailpipe. Rapidly increase the engine speed to around 2500 rpm, or half the maximum engine speed if this is lower, and assess; c) the smoke emitted from the tailpipe. 2. Check the exhaust tailpipe(s) for shape, accessories/shield, restriction etc that prevents the insertion of the meter probe.

3. All vehicles except mopeds, 3 wheel mopeds and light quadricycles. Using an exhaust gas analyser and following the manufacturers instructions determine the proportions of; a) carbon monoxide (CO), over a period of at least 5 seconds at idle.

Reasons for Failure

1. The engine; a) idles at a speed clearly above its normal idle speed, b) emits dense blue or clearly black smoke for a continuous

period of more than 5 seconds at idle, c) emits excessive smoke or vapour of any colour during acceleration which would obscure the view of other road users .

2. The emissions cannot be measured because a tailpipe accessory is fitted which prevents insertion of the meter probe. 3. The exhaust gas contains; a) a carbon monoxide (CO) content exceeding the required limits for a continuous period of 5 seconds.

Section 20 - Exhaust Emissions (diesel) N/A

Section 21 - Brake Performance

Application

This Inspection applies to all vehicles unless specified in bold text.

Requirements and procedures

1. Using a roller brake tester, carry out a brake test following the RBT operating instructions, check; a) service brake performance, b) secondary brake performance (3/4 wheel vehicles only), c) parking brake performance (3/4 wheel vehicles only), d) for a sticking or binding brake, e) for severe grab or judder, f) the braking effort rises and falls at about the same rate as the effort applied, g) any brake imbalance between two wheels on a steered axle is not more than 30% (3/4 wheel vehicles only). Notes. Any braking system will be considered to have met the performance requirements if more than half the wheels lock. Serious under inflation of tyres is not a reason for failure, however a tester may decide not to conduct a brake test if tyre damage is likely. When using a roller brake tester the wheel not on the rollers must be braked and chocked against the reaction force. This is especially important for lightweight machines and those with small wheels. In the case of a linked brake system, it may not be possible to apply the brake of the wheel not being tested prior to starting the test. If a roller brake test is repeated, the chock should be removed, the machine resettled in the rollers and the chock replaced. The retardation force of a side car brake is not to be included unless it is operated by one of the motorcycle brake controls. The efficiency of each system operated by a single brake control is the ratio of the total retarding force generated by that system divided by the weight of the machine and rider. Efficiency % = Total retarding force for one system x 100 Weight of machine plus rider (tester)

Most machines have two controls, one operating the front wheel brake and the other the rear wheel brake. The efficiency for front and rear wheels can then be calculated as above. Where a linked or combined system is operated by one control, the retarding force used in the efficiency calculation is the total from both wheels when operated by that control only. In this case, the other control will probably

operate on one wheel.

Reasons for failure

1. a) service brake performance below; (i) 40% for the front wheel (32% for mopeds), (ii) 27% for the rear wheel (25% for mopeds), (iii) 50% for vehicles with a combined system, (iv) 28.5% for each system for tricycles with 2 independent systems, b) secondary brake performance below 23%, c) parking brake performance below 18%, d) a sticking or binding brake, e) severe brake grab or judder, f) the braking effort does not rise or fall at about the same rate as the effort applied, g) a brake imbalance between two wheels on a steered axle of more than 30%.

Section 22 - Goods Vehicle Identification Plate N/A

Section 23 - Engine Power Restriction Information Plate

Application

This examination applies to 2 wheeled mopeds (Category A) and motorcycles capacity not exceeding 125cc and a power output not exceeding 11kW (15bhp) (Category B). This examination does not apply to amateur built vehicles, rebuilt vehicles, vehicles manufactured using the parts of a registered vehicle fitted with engines manufactured before 1 January 1993.

N/A

Section 24 - Defrost/Demist N/A

Section 25 - Seat Belts and Anchorages N/A

Section 26 - Glazing N/A

Section 27 - Windscreen Wipers and Washers N/A

Section 28 - Masses and Dimensions

Application

This inspection applies to all vehicles


1. Visually check dimensions only. If in doubt vehicle meets the requirements then measure. 2. The maximum unladen vehicle mass must be declared on the test application form. The declared weight of the vehicle should be verified when carrying out the RBT test. In extreme circumstances the vehicle may be weighed at the start of the examination.

MAXIMUM VEHICLE MASSES

VEHICLE MAXIMUM UNLADEN MASS

Moped As Manufacturers Declaration

3 Wheel Moped 270 kg

Light Quadricycle 350 kg

Motorcycle As Manufacturers Declaration

Heavy Quadricycle 400 kg

Heavy Goods Quadricycle 550 kg

Tricycles 1000 kg

Reasons for Failure

1. Any vehicle which does not meet dimensional requirements. 2. Any vehicle with an unladen mass clearly heavier than is required for its class.

DIMENSIONS FOR ALL VEHICLES

LENGTH 4.0 M

WIDTH 2.0 M 1.00 M For Two Wheel Mopeds

HEIGHT 2.50 M

0209161 MSVA01 Ministers Cert Oct 08 23/10/08 17:34 Page 1

Motorcycle Single Vehicle Approval

Application for a Minister’s Approval Certificate Motor Cycles Etc. (Single Vehicle Approval) Regulations 2003

MSVA1 (October 2008)

Please read the notes on pages 3 and 4 before completing your application. Failure to complete the form accurately may cause delay.

* For official use only *NR

1. Vehicle identification number (In full): This information, VIN, frame or chassis number, is likely to be found on the manufacturer’s data plate located on the frame or, in the case of car based vehicles, under the bonnet or around the door aperture. Where the number is considered to be inadequate you will be referred to your DVLA Local Office for them to allocate a suitable number.

2. Vehicle make: Vehicle model:

3. a) Vehicle type: (✓) Moped Low powered moped

Please see page 3 for definitions of types Motorcycle Motorcycle & sidecar

Motor tricycle

Light quadricycle Heavy quadricycle

b) Is the vehicle designed to carry goods? (✓) Yes No

c) Moped only Number of wheels: 2 3

d) Motorcycle & sidecar only Which side of the vehicle is the sidecar on? Right Left

4. Vehicle category: Amateur built Rebuilt

Vehicle manufactured using parts of a registered vehicle Please see page 3 for definitions. If none apply please leave blank.

5. Is the vehicle built from a kit? (✓) Yes No

Is it a special/custom vehicle built from the ground up? (✓) Yes No

6. Where would you like the vehicle tested? First choice

Second choice

Please provide a second choice of test station, as the first may not be available. Some stations can only carry out tests on certain vehicle types, please refer to the list on page 4 for details. NB Retests must be carried out at the same station as the original test.

7. When would you like the test?

8. At what time would you like the test?

You will be given an appointment as near to your choice as possible. Out of hours testing may be available at certain test stations. This will be before 8.00am or after 5.00pm on a Monday to Thursday, before 8.00am or after 4.30pm on a Friday or at any time on a Saturday, Sunday or Bank Holiday. A supplementary fee is payable for testing outside normal working hours.

9. Value of enclosed cheque/postal order or customer account number:

10. Contact name:

Company name (if applicable)

Applicant’s UK address or address to

which appointment letter is to be sent:

Please ensure details are entered in

full and include the Post Code

Contact numbers:

email address:

Postcode:

Tel: Fax:

Page 1


11. Does the vehicle have full bodywork? (✓) Yes No A bodied vehicle is defined as ‘a vehicle with a structure consisting/comprising of a floor plan and panels which with a roof fully encloses the vehicle occupants and without a roof encloses them other than where a roof would be’.

12. Date of manufacture (month and year): This information should be obtainable from the manufacturer’s data plate, the owner’s manual or from the manufacturer or their agent.

13. Date of manufacture of engine: Only required for vehicles which fall into the categories listed at question 4 above.

14. Engine details: *Petrol 2 stroke / Petrol 4 stroke / Diesel / Other e.g. LPG, electric

*Turbocharged / Non-turbocharged

Transmission type: *Manual / Automatic *Delete as appropriate

Engine capacity:

Fuel tank capacity:

Engine / motor maximum power output:

Weight of batteries:

cc

litres

bhp/PS/kW*

kg

The weight of batteries is required for electrically propelled vehicles only.

15. Vehicle weights: Unladen weight: kg Goods Vehicle Payload: kg

Gross design weights: (Only required for goods vehicles)

Axle 1 kg Axle 2 kg Axle 3 kg Gross kg Train kg

This information should be obtainable from the manufacturer’s data plate, the owner’s manual or from the manufacturer or their agent. If the vehicle is powered by an electric motor these weights should not include the weight of the batteries.

16. Maximum road speed:

Maximum power engine speed:

mph

rpm

This information should be obtainable from the owner’s manual or from the manufacturer or their agent.

17. Is the vehicle fitted with an anti-lock braking system? (✓) Yes No

Is the vehicle fitted with a linked braking system? (✓) Yes No

Data Protection The personal information you provide on this form will be used for the purposes of VOSA's statutory functions. It will not be disclosed to other organisations unless required or permitted by law. For further information, visit our Information Charter available from VOSA’s website: www.vosa.gov.uk.

DECLARATION I declare that, to the best of my knowledge and belief, all statements in this application are true.

Full name .................................................................................... Signature .........................................................................

Date ............................................................................................

Please ensure that this declaration is signed. Failure to do so will result in a rejection of your application. WARNING Any person who knowingly or recklessly makes a false statement is liable on conviction to a heavy penalty (see Section 174(2) of the Road Traffic).

On completion please send your application, together with the appropriate fee, either to the test station of your choice (please see list on page 4) or to VOSA, MSVA, PO Box 82, Swansea, SA1 1HQ. Cheques and postal orders should be crossed and made payable to ‘VOSA’. Please do not send notes, coins or Giro transfers in the post. For details on customer accounts please contact any test station or call the VOSA national number on 0300 123 9000. We are also able to accept MSVA applications via email from customers with a customer account. If you hold a VOSA customer account and wish to submit applications via email please contact your nearest test station for details.

For further information ● visit our website at www.transportoffice.gov.uk or ● call the VOSA national number on 0300 123 9000 (Calls provided by BT are charged at a low rate. Charges from other providers may vary.)

Page 2


Definitions of vehicle types:

Mopeds Low powered moped

● a moped with pedals, ● with auxiliary propulsion not exceeding 1kW, and ● a maximum design speed not exceeding 25km/h (16mph).

2 wheeled vehicle ● with a maximum design speed not exceeding 45km/h (28mph) (48km/h [30mph] if manufactured before 08/08/03), ● fitted with an internal combustion engine having a cylinder capacity not exceeding 50cc, or ● fitted with an electric motor with a maximum continuous power not exceeding 4kW.

3 wheeled vehicle ● with a maximum design speed not exceeding 45km/h (28mph) (48km/h [30mph] if manufactured before 08/08/03), ● fitted with a spark ignition internal combustion engine having a cylinder capacity not exceeding 50cc, or ● fitted with any other internal combustion engine which has a maximum net power output not exceeding 4kW, or ● fitted with an electrical motor with a maximum continuous power not exceeding 4kW, ● not exceeding 270 kg unladen, and ● if designed to carry goods a payload not exceeding 300kg.

4 wheeled vehicle (light quadricycle) ● with a maximum design speed not exceeding 45km/h (28mph) (48km/h [30mph] if manufactured before 08/08/03), ● fitted with a spark ignition internal combustion engine having a cylinder capacity not exceeding 50cc, or ● fitted with any other internal combustion engine which has a maximum net power output not exceeding 4kW, or ● fitted with an electrical motor with a maximum continuous power not exceeding 4kW, ● not exceeding 350kg unladen, and ● if designed to carry goods a payload not exceeding 200kg.

If any of the above moped classes are powered by an electric motor the weight of the batteries must not be included in the unladen weight. A vehicle fitted with an electrical motor with a maximum continuous power of more than 4kW will be classed as a Motorcycle or Motor Tricycle as appropriate.

Motorcycles 2 wheeled vehicle

● with or without sidecar, ● fitted with an internal combustion engine having a cylinder capacity of more than 50cc and/or a maximum design

speed of more than 45km/h (28mph).

Motor Tricycles 3 wheeled vehicle (with 3 symmetrically arranged wheels)

● fitted with an internal combustion engine having a cylinder capacity of more than 50cc and/or a maximum design speed of more than 45km/h (28mph),

● not exceeding 1000kg unladen, and ● if designed to carry goods a payload not exceeding 1500kg.

4 wheeled vehicle (heavy quadricycle) ● fitted with an internal combustion engine having a cylinder capacity of more than 50cc and/or a maximum design

speed of more than 45km/h (28mph), ● the maximum net engine power not exceeding 15kW, ● not exceeding 400kg unladen (550kg for goods vehicles), and ● if designed to carry goods a payload not exceeding 1000kg, ● the weight of the batteries not being included in the unladen weight.

Definitions of vehicle categories:

Amateur built vehicle A vehicle constructed or assembled:

● for the personal use of the applicant, ● by the applicant, or by individuals acting on behalf and under the direction of the applicant, ● by persons not in the business in which motor vehicles are normally constructed or assembled.

Rebuilt vehicle A vehicle which:

● is not an amateur built vehicle within the meaning given above and is not a vehicle manufactured using parts of a registered vehicle within the meaning give below,

● has been rebuilt using a replacement chassis, or an integral chassis body, which was supplied for the purpose without having been previously used, or previously formed part of a registered vehicle,

● is of the same design and construction as the original vehicle. Vehicle manufactured using parts of a registered vehicle A vehicle constructed or assembled:

● by a person carrying on a business in the course of which motor vehicles are normally constructed or assembled, ● using a previously used engine and one or more of the following components taken from the same previously

registered vehicle: chassis or frame, body, suspension, a braked axle with more than one wheel, transmission, or steering assembly.

Page 3


MSVA TEST STATIONS NB Testing of 2 wheeled vehicles is only available at stations marked B. Testing of 3 and 4 wheeled vehicles is only available at stations marked T. ● Aberdeen B/T - Cloverhill Road, Bridge of Don Industrial Estate, Aberdeen. AB23 8FE � 01224 702357 ● Beverley B/T - Oldbeck Road, Off Grovehill Road, Beverley, North Humberside. HU17 0JW � 01482 881522 ● Birmingham (Garretts Green) T - Garretts Green Industrial Estate, Birmingham. B33 0SS � 0121 783 6560 ● Birmingham B - Unit 10, Elmdon Trading Estate, Birmingham. B37 7HE � 0121 782 4389 ● Bristol (Avonmouth) B/T - Merebank Road, Bristol, BS11 8AQ � 0117 938 1157 ● Cardiff (Llantrisant) B/T - School Road, Miskin, Pontyclun. CF72 8YR � 01443 224701 ● Carlisle B/T - Brunthill Road, Kingstown Industrial Estate, Carlisle, Cumbria. CA3 0EH � 01228 528106 ● Chelmsford B/T - Widford Industrial Estate, Chelmsford, Essex. CM1 3DR � 01245 259341 ● Derby B/T - Curzon Lane, Alvaston, Derby. DE21 7AY � 01332 571961 ● Exeter B/T - Grace Road, Marsh Barton Trading Estate, Exeter, Devon. EX2 8PU � 01392 217276 ● Gillingham B/T - Ambley Road, Gillingham, Kent. ME8 0SJ � 01634 232541 ● Glasgow B/T - Crosshill Road, Bishopbriggs, Glasgow. G64 2QA � 0141 772 6321 ● Kidderminster B - Worcester Road, Kidderminster, Worcestershire. DY11 7RD � 01562 745857 ● Leighton Buzzard B/T - Stanbridge Road, Leighton Buzzard, Bedfordshire, LU7 4QG � 01525 373074 ● Liverpool B - Stopgate Lane, Simonswood, Kirby, Liverpool, L33 4YA � 0151 547 4445 ● London North (Edmonton) T - Towpath Road (off Harbet Road), Lea Valley Trading Estate, Edmonton. N18 3JR � 0208 807 7803

● London South (Mitcham) B/T - Redhouse Road, Croydon, Surrey. CR0 3AQ � 0208 684 1499 ● London West (Yeading) T - Cygnet Way, Willow Tree Lane, Yeading, Hayes, Middlesex. UB4 9BS � 0208 841 9205 ● Manchester North (Chadderton) B/T - Broadway Business Park, Broadgate, Chadderton, Oldham. OL9 9XA � 0161 947 1000 ● Newcastle B/T - Sandy Lane, Gosforth, Newcastle upon Tyne. NE3 5HB � 0191 236 5011 ● Norwich B/T - Jupiter Road, Hellesden, Norwich. NR6 6SS � 01603 408128 ● Shrewsbury B/T - Ennerdale Road, Harlescott, Shrewsbury, SY1 3LF � 01743 462621 ● Southampton (Northam) B/T - Units R&S, Centurian Industrial Park, Bitterne Road West, Southampton. SO18 1UB � 02380 837397

● Taunton B/T - Taunton Trading Estate, Norton Fitzwarren, Taunton, Somerset. TA2 6RX � 01823 282525 ● Watford B - Unit A, Caxton Court, Caxton Way, Watford. WD18 8RH � 01923 814093

MSVA does not apply to the following vehicles: ● Vehicles over ten years old. ● Vehicles with a maximum design speed not exceeding 6km/h. ● Cycles with pedal assistance which are equipped with an auxiliary electric motor having a maximum continuous rated

power of 0.25kW, of which the output is progressively reduced and finally cut off as the vehicle reaches a speed of 25km/h, or sooner, if the cyclist stops pedalling.

● Vehicles intended for pedestrian control. ● Trial or enduro motorcycles intended for use in competitions, on roads or whatever the terrain.

Trial motorcycles are defined as having the following characteristics: a) maximum seat height of 700mm, b) minimum ground clearance of 280mm, and c) maximum fuel tank capacity of 4 litres.

Enduro motorcycles are defined as having the following characteristics: a) minimum seat height of 900mm, and b) minimum ground clearance of 310mm.

● Agricultural tractors, off road tractors, agricultural engines or light agricultural vehicles, as defined below. Agricultural tractor - a tractor used on public roads solely for purposes relating to agriculture, horticulture, forestry or activities falling within:

a) cutting verges bordering public roads; b) cutting hedges or trees bordering public roads or bordering verges which border public roads.

Off road tractor - a tractor which is not an agricultural tractor and which is: a) designed and constructed primarily for use other than on roads, and b) incapable by reason of its construction of exceeding a speed of 25mph on the level under its own power.

Agricultural engine - a machine specially designed/converted to perform an agricultural operation on the land (e.g. a combine harvester). Light agricultural vehicle - a vehicle which:

a) has a revenue weight not exceeding 1000kg, b) is designed and constructed so as to seat only the driver, c) is designed and constructed primarily for use other than on roads, and d) is used solely for purposes relating to agriculture, horticulture or forestry.

● Vehicles designed primarily for off-road leisure use having wheels arranged symmetrically with one wheel at the front and two at the rear.

● Vehicles adapted or constructed to enable use by a disabled person (i.e. a person who has a disability as defined in section 1 of the Disability Discrimination Act), whether as driver or passenger.

MSVA1 October 2008 - VOSA 33 Page 4

yamaha 450/660/700 road legal conversion - quadtechquadtech.co.uk/msva/yamahasport_2010.pdf ·...

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