TÜV rules for motorbike conversion

TÜV - Rules and regulations for motorbike conversions. What should be considered before the conversion, what are the TÜV rules for motorbikes and what is the best way to proceed?

Mirrors: 
-Mirrors are not subject to registration
-at least 60 cm² until first registration in 2003
-At least 68 cm² from first registration in 2003.
-Until 1990 one mirror on the left side is sufficient, from then on there must be two.

Seat:
-Seat benches are not subject to registration.
-the number of seats is subject to registration
-a double bench seat must have a minimum length of 600mm
-up to a length of 650mm there must be a restraint facility
-a single seat bench must have a minimum length of 300mm

Handlebars:
-Handlebars are subject to registration or must have an ABE available
-Handlebars must be tested parts
Handlebars from the off-road sector without a certificate / ABE are not permitted.
-The height of the handlebars above the seat must not exceed 500 mm. 
-The handlebars must not pinch the fingers (e.g. towards the tank).
-drillings to fix the fittings are allowed
-drillings between the clamps for routing the cables allowed.

Number plate holder:
-Number plate holders in the middle of the vehicle are not subject to registration.
-Lateral licence plate holders are subject to registration.
The lower edge of a licence plate must be at least 300 mm from the road surface when the vehicle is loaded, but the upper edge must not be more than 1200 mm from the road surface. It may have an inclination of max. 30 degrees. Especially in the case of a lateral licence plate holder, it must be ensured that this can be read from the rear at an angle of 30°. 

Wheel cover:
-Wheel covers (mudguards) are not subject to registration.
-For motorbikes, the STVZO stipulates a rear wheel cover of 150 mm above the axle centre 
 the centre of the axle and a complete covering of the tread.
-For motorbikes with EC approval, no specific wheel cover is prescribed.
-A shortened wheel cover is theoretically also possible for non-EC-approved motorcycles. 
 ultimately a matter of interpretation by the inspector. As a rule, rear mudguards that extend to the middle above the wheel are accepted.
Attention: The licence plate does not count as a cover. The installation regulations for reflectors and rear lights must be observed.

Lights and signalling equipment:
Headlights, rear lights and indicators are not subject to registration. All headlights and tail lights must bear a test mark: "test snake" or E mark. All turn signals must have an approval mark that identifies them as turn signals. This is R50 and the number 11 for the front, or 12 for components radiating to the rear. Yellow headlights (except fog lights) are not permitted in Germany. 

Parking light:
-not subject to registration
-Required according to EC, not according to StVZO.
-According to EC also 2 permissible
-According to EC, mounted symmetrically to the longitudinal centre of the vehicle, according to StVZO only in the headlamp.
-according to EC in height 350 mm - 1,200 mm, according to StVZO up to 1,500 mm

Low beam / high beam:
-not subject to registration
-At least 1 headlight required
-One headlight must be mounted in line with the longitudinal centre of the vehicle.
-double headlamps are generally permissible
-The maximum distance between 2 headlamps is 200mm. 
-the mounting must be symmetrical to the longitudinal centre of the vehicle
-height of headlamps 500 - 1,200 mm
blue switch-on indicator lamp required for main beam (EC), according to StVZO also indication by switch position  
 by switch position permissible

Fog lights:
-not subject to registration
-number according to STVZO 1 max. 250 mm from the longitudinal centre of the vehicle, also permitted on crash bars
-according to EC also 2 permitted symmetrical to longitudinal centre of vehicle
-max. same height as low beam headlamps
-Fog lamps may only function together with the dipped beam.
-Fog lights must have an ECE approval mark.
-Yellow fog lights are permitted

Direction indicators:
-Not subject to registration
-prescribed, according to StVZO from EZ 01.01.1962 4 pieces
-Front markings: 1, 1a, 1b, 11
-marking rear: 2a, 2b, 12
-width according to EC 240 mm front, 180 mm rear, according to StVZO 340 mm front, rear  
 240 mm 
-in height: 350 - 1,200 mm
-indicator lights at the handlebar ends ("bull's eyes") to each other 560 mm
-Ox-eyes after EZ from 01.01.1987 only permissible in conjunction with additional rear turn signals
Switch-on check prescribed by EC, permissible according to StVZO

Brake light:
-not subject to registration
-prescribed according to EC, also 2 permissible
-prescribed according to StVZO only from EZ 01.01.1988 number 1
-in mounting position: central
-height: lower edge min. 250 mm (according to StVZO min. 350 mm), upper edge max. 1,500 mm

Tail light:
-not subject to registration
-prescribed; number 1 or 2
-mounting position: central
-in height min. 250 mm, max. 1,500 mm
-max. distance to end of vehicle 300mm

Number plate light:
-not subject to registration
-mandatory at the rear

Reflector:
-not subject to registration
-prescribed, not triangular
-in height min. 250 mm, max. 900 mm
-If integrated in the rear light, no additional reflector necessary.

Air filter (single air filter):
-are subject to registration
-as a rule, a power and noise measurement is required
-There are no certificates for them, registration must be done by individual approval.
-From 1989 onwards, an exhaust emission certificate is required. This is theoretically possible, but due to the 
 but not in practice due to the extremely high costs. 
Individual filters (K&N or DNA) can be registered by individual approval. The requirements for this depend on the respective inspection authority and can vary greatly in terms of both effort and cost. As a rule, a performance and noise measurement is required. This requires a vehicle that is ready to drive and otherwise in a state suitable for registration. 

Exhaust systems:
-Are subject to registration or must have an ABE.
-Systems with EC type approval have an E-number stamp (large "E" with number in a square), papers do not have to be carried. 
-For systems with an ABE, the ABE must be carried at all times. 
Self-built vehicles are subject to registration; as a rule, power and noise measurements are required. From 1989 onwards, an exhaust emission certificate is required. This is possible in theory, but not in practice due to the high costs. 
The registration of exhaust systems without ABE or expert opinion can be done by individual approval. The requirements for this depend on the respective inspection authority and can vary greatly in terms of both effort and cost. As a rule, a performance and noise measurement is required. This requires a vehicle that is ready to drive and in a condition that is otherwise suitable for registration. 

Driving noise limits:
EZ to 13.09.53 90 Phon 
20.05.56 87 Phon 
31.12.56 84 Phon 
12.09.66 82 Phon 
30.09.83 84 dB(A)N 
30.09.90 82 dB(A)N 
30.09.95 82 dB(A)N
from 01.10.95 80 dB(A)N 
The standing noise is only a comparative value and is not subject to any restrictions.

Frame/subframe:
-Modifications are always subject to registration.
-Tail frames should have a parts certificate
-Own constructions without an official certificate according to §19.2 or §19.3 are normally 
 not eligible for registration  
-The shortening or modification of a frame/rear frame can, under certain circumstances, be 
 (depending on the test engineer).

Brake system:
-Modifications are subject to registration.
-Brake lines are subject to registration or must have an ABE.
-Brake discs are subject to registration or must have an ABE.
-Brake pads must have national (KBA no.) or international (EC or ECE no.) approval.
-marking) approval
-when fitting original brake components from another vehicle, the 
 test engineer is required. In this case, there is a parts test of the original vehicle. In this case, registration can be effected by individual acceptance; the requirements for this depend on the respective test centre and can vary greatly in terms of both effort and cost.

Tyres:
-Changes are subject to registration.
-If a clearance certificate from the manufacturer is available, registration by the TÜV is usually uncomplicated. 
 by the TÜV is usually uncomplicated.
For tyre conversions for which there is no certificate, registration by individual inspection is required. The following rules must be observed:
-The tyre size must match the rim size. As a rule, tyre manufacturers specify in their 
 technical tables which rim dimensions are required for the tyre in question. 
 are required.
-The speed index of the tyres must be at least 10 km/h higher than the maximum speed stated in the papers. 
 the maximum speed specified in the papers.
-An exception applies to M&S tyres. These winter tyres are permitted up to a maximum speed of 160 km/h 
 and may also be fitted to vehicles whose registered maximum speed is 
 maximum speed is higher. A marking "Max. 160km/h" must be affixed to the speedometer (sticker). 
 (sticker) must be affixed to the speedometer.  
-The free movement of the tyres must be guaranteed. Here we assume 
a minimum distance of 5 mm from vehicle components to the side of the tyre. Lengthwise 
it must be noted that the tyre grows at higher speeds. Here we ensure a minimum distance of 10mm.
However, these points are no guarantee that your local TÜV office will register your tyres. So it's better to check with them before fitting.

Side/main stands:
-are not subject to registration
-A side stand and/or a main stand must be available.
-It must not be possible to ride off with the stand unfolded.

Footrests:
-are subject to registration or must have an ABE (general type approval)
-The number must correspond to the number of seats (2 per seat).

Carrier systems, panniers, luggage racks:
-are not subject to registration.
-The mounting must not have any influence on parts relevant to registration or safety.

Fairing parts:
-are subject to registration
-If no parts certificate is available, it is advantageous to have at least a material certificate. 
 have
-in the case of original parts, there is a parts inspection of the original vehicle
In both cases, registration can be effected by individual approval; the requirements for this depend on the respective inspection authority and can vary greatly in terms of both effort and cost. 

Basically 
It is best to talk to the test engineer before the conversion. 
Fortunately, there are many TÜV test engineers who have a great affinity for motorbikes and have the corresponding competence to evaluate such conversions and also to approve them. You need such an inspector!
However, there are also inspectors who do not want to take on this responsibility and do not want to make any registrations without an expert opinion or a clearance certificate. If the vehicle is a 300km/h fast S1000RR, one can have some understanding for this. Should you come across such a test engineer, I would recommend that you break off and go to another TÜV office.