Screwdriver tip for the check before the main inspection

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Screwdriver tip for the check before the main inspection
Ralf Petersen

Screwdriver tip for the check before the main inspection

Screwdriver tip for the check before the main inspection

Screwdriver tip for the check before the main inspection

Screwdriver tip for the check before the main inspection

14th pictures

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Don’t forget: papers, ABEs, tire approvals and a key for the steering lock.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Only with certification mark: indicators and other parts of the lighting system must have the E mark.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Nothing flashes anymore? Problems can often be eliminated with cleaning and contact spray.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Typical error: The activated sidestand switch must interrupt the ignition.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Unobstructed view: If the thickness of the lining is not easy to see, the brake calliper can be removed.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Play and locking point: The steering head bearing is always checked very carefully at the general inspection.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Frequent annoyance: telescopic fork leaks are classified as a serious defect.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Tire control: Correct tread depth, correct installation, damage and approvals?

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Clean combustion? The AU makes possible errors in the engine setting visible.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Indispensable: The test drive at the general inspection reveals weaknesses in the chassis and brakes.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Often overlooked: After a rear light conversion, the license plate lighting may be faulty.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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All plaketti: with a new plaque from the farm, no problem thanks to good preparation.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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This is required for maintenance: flashlight, profile knife, various lubricants / care products, chain spray, contact spray / WD 40, small mirror, candles and candle wrenches, copper paste, new air filter.

Screwdriver tip for the check before the main inspection
Ralf Petersen

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Ralf Petersen works as a further education teacher at the VHS Duisburg and has been organizing mechanics courses for 22 years. 12 to 15 practical seminars on maintenance, repair and technology are offered every year. www.motorrad-schrauberkurse.de

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Screwdriver tip for the check before the main inspection

Screwdriver tip for the check before the general inspection
What to consider before the main inspection

Motorcycles have to go through the general inspection, commonly known as TuV, every two years. A look at the papers or the badge provides information about the exact date. 15 percent of all test items do not receive a badge straight away. Whether TuV, Dekra, GTu or KuS – we show what is being tested and what good preparation looks like.

05/04/2021

In this article:

  • Lighting / electrical system
  • Brakes
  • Wheel bearings and steering
  • Spring elements
  • tire
  • Emission test for motorcycles
  • Exhaust system
  • Then the appointment at the TuV
  • Short test drive
  • Allocation of the badge
  • 1 month for rectification of defects
  • Mechanic courses

The first impression counts, and to a certain extent this also applies to the HU. The machine should therefore be in a reasonably presentable condition visually. A rusted chain, for example, is a clear indication of insufficient maintenance. A small cleaning / maintenance unit is therefore appropriate, and hidden defects are often found on this occasion. This is all the more true if relatively little has been driven since the last general inspection, because damage to the vehicle is a frequent cause of defects. And most motorcycles have to go to the general inspection in spring, often after a long break from driving. An extensive test drive is therefore not a mistake, because the examiner will of course also do a (mini) lap. You should pay particular attention to the proper functioning of the suspension, chassis unrest, squeaking / noises etc. as well as a spongy braking effect. After the journey, you then check the engine, transmission, cooling lines, etc. for leaks. If there are no abnormalities, you can continue with a short check of the most important test points, which can be carried out relatively easily yourself without great effort. Prepared in this way, you save nasty surprises at the appointment.

Lighting / electrical system

It is best to start with the lighting / electrical system. All lamps must be E-marked, fully functional, and glasses or housings must be undamaged. This also applies to the instrument and license plate lighting. The reflector from the main headlight must not be blind and the headlight must not be set too high. Additional headlights must be switched according to the regulations (daytime running lights etc.).


Screwdriver tip for the check before the main inspection


Ralf Petersen

Only with certification mark: indicators and other parts of the lighting system must have the E mark.

Don’t forget to check the brake light switch at both the front and rear, as well as the hazard warning lights (if present), horn and kill switch. The inspectors pay special attention to the function of the safety switch on the side stand. If installed, the engine must go out with the stand folded out and the gear engaged. The cause of any problems that may arise in this area are usually corrosion or loose plug connections. The fault can often be easily eliminated by cleaning and / or using a contact spray.

Brakes

After you have checked that it is working properly during the test drive, you also start a visual inspection of the brakes. The brake discs must not be scratched or heavily worn, and brake lines must not have any leaks, chafe marks or kinks. The coverings should have sufficient residual strength. Depending on the design, the best way to do this is to shine a flashlight into the brake caliper from below, above or from the front. Even a small mirror can sometimes do a good job. Most brake pads have wear marks that indicate whether the pads need to be replaced. If the thickness of the pads cannot be assessed precisely in this way, the brake calliper should be removed so that you can have an unobstructed view of the pads.


Screwdriver tip for the check before the main inspection


Ralf Petersen

This is needed for maintenance: flashlight, profile knife, various lubricants / care products, chain spray, contact spray / WD 40, small mirror, candles and candle wrenches, copper paste, new air filter.

Wheel bearings and steering

Like the brakes, the chassis / steering components are also highly relevant to safety and are therefore checked particularly thoroughly during the general inspection. A simple test of the wheel bearings is carried out with the machine jacked up; the wheel to be tested must not be in contact with the ground. If you grip the wheel as far as possible and try to move it in the bearings, you can feel any play that may be present. The following applies to bearings: if they are defective, they must be replaced. Checking the steering head bearing is a little more complicated. With the front wheel unloaded, grasp the fork at the lower ends and try to move it back and forth slightly. If there is play, the bearing is too loose and must be readjusted. It is then checked whether a so-called rest point can be felt. To do this, you turn the wheel (or the handlebar) slowly and sensitively back and forth. If the balls or rollers of the bearing have worked in and are therefore in the middle position “get stuck”, this locking point is noticeable. In this case the bearing must be changed. A bearing that is set too tightly is also noticed during this check. Finally, the problem-free function of the steering lock is on the agenda. If it gets stuck or jams, the problem can usually be resolved by cleaning and lubricating the bolt.

Spring elements


Screwdriver tip for the check before the main inspection


Ralf Petersen

Frequent annoyance: telescopic fork leaks are classified as a serious defect.

The next point is the spring elements. If a film of oil is visible on the stanchions of the telescopic fork, the fork seal rings are defective and must be replaced. In some machines, e.g. B. Enduros or young timers, bellows are mounted. For testing, these are loosened and lifted at the lower fastening. Also, no oil leakage should be visible on the piston rods of the rear suspension struts.

tire

The tires must have a sufficient tread depth (at least 1.6 millimeters). Furthermore, the direction of travel must be correct and the tire surface must be free of cracks or damage. Anyone who has fitted a different pair of tires than specified in the papers must not forget the corresponding clearance certificates. Due to the new regulations regarding different tire sizes, if you have still installed tires with the production year 2019 and earlier, you can use the opportunity to (still!) Easily register the tires. With just under 40 euros and a visit to the admissions office, the topic is then permanently settled.

Emission test for motorcycles

A special chapter is the exhaust gas test for motorcycles, which were registered for the first time after January 1st, 1989. The upper limit for CO emissions for motorcycles without a catalytic converter is usually 4.5 percent by volume and for models with a regulated catalytic converter it is 0.3 percent by volume. These specifications are usually not a problem with a well-adjusted machine. If you are unsure, you should check the following points: Tighten, seal or change incorrectly seated or porous intake ports, clean or replace dirty air filters. Worn spark plugs, poorly adjusted carburettors and incorrect valve clearance can also have a negative impact on exhaust gas values. Often, however, extensive warming up at medium to high speeds is sufficient, as this blows the combustion chambers as well as the intake and exhaust ducts free. So it can make sense to plan a little detour on the way to the test center.

Exhaust system

The exhaust system should also be inspected. Loose screws at connection points and defective seals increase the noise level and can lead to difficulties.

Then the appointment at the TuV


Screwdriver tip for the check before the main inspection


Ralf Petersen

Play and locking point: The steering head bearing is always checked very carefully at the general inspection.

My appointment at the TuV, of course after prior registration and consultation with regard to photo approval, etc., was almost like a school. Examiner Dietmar Bley from the test center in Mulheim kindly took a lot of time for explanations and tips. After checking the vehicle data (chassis number, etc.), it was time to carry out numerous modifications to the Sevenfifty. Handlebars (ABE), steel braided cables (ABE), LED indicators, rear light conversion plus additional license plate lighting (with corresponding test marks), tires (Conti Road Attack 3 with approval) and the self-made, naturally registered four-in four exhaust systems were examined and compared with the information.

Short test drive

This was followed by the obligatory short test drive, which can be more extensive in the event of anomalies. The rest of the HU took place in the hall. In contrast to motorists, motorcycle customers are actively involved in the test process. It starts with jacking up the machine, followed by checking the lights and electrical system, and assistance is also required in relieving the front wheel by pushing it down, which is necessary for the chassis check. Any complaints can of course not be discussed away. However, explanations can be quite useful. My blinkers, which were a little weakly lit, were due to the battery, which had become a bit weak due to the longer standing time. With the engine running and the alternator powered, the problem was resolved immediately. Basically, you should seek a dialogue for possible solutions in the event of deficiencies. The auditor’s tips are often worth cash.


Screwdriver tip for the check before the main inspection


Ralf Petersen

Indispensable: The test drive at the general inspection reveals weaknesses in the chassis and brakes.

The emissions test was also quite interesting. For motorcycles without a catalytic converter, the upper limit for CO emissions is 4.5 percent by volume and for models with a regulated catalytic converter, 0.3 percent by volume. The 26-year-old Sevenfifty achieved good values ​​here and was in the green with just under 0.7 percent. My NTV 650 with water cooling and double ignition even achieved the value of catalytic converter vehicles with 0.16 percent. Good maintenance also pays off from an environmental point of view.

Allocation of the badge

So the allocation of the badge was purely a matter of form, and there was still time for a little chat. According to Bley, the often low mileage between the HU appointments is astonishing. Only a few 100 kilometers are not uncommon. There are also brand-specific irregularities. Harleys often have problems with the exhaust system and BMWs with the AU if the battery was removed / disconnected shortly beforehand and the engine management system no longer works properly. Some reactions from customers are also amusing: “It’s normal for it to oil, it’s an old motorcycle.” “It doesn’t matter if the front brake doesn’t work, I only brake at the rear anyway.” “You can stick the badge in spite of the flaws, I am selling the machine anyway.”

Most of the time, the problems are homemade. After beautification measures such. B. Rear conversions are often missing reflectors, or the license plate lighting does not work properly after replacing the rear light (distance to the upper edge / angle). Add-on parts without ABE, tires without approval as well as stylish but too small mirrors are other typical defects.

1 month for rectification of defects

If the badge didn’t work the first time, the owner usually has a month to remedy the defects. If you let this deadline pass, you have to do a complete HU including the full costs (approx. 75 euros). For the follow-up examination, in addition to the vehicle registration document, you must also present the examination report of the first examination. As a rule, only the impairments that are recorded in the defect report are checked. The price of this follow-up examination is between 15 and 30 euros, depending on the scope.

Mechanic courses

The author, Ralf Petersen, works as a further education teacher at the VHS Duisburg and has been organizing mechanics courses for 22 years. 12 to 15 practical seminars on maintenance, repair and technology are offered every year. His book was published by Delius Klasing Verlag in 2015 “Basic knowledge of motorcycle technology”. Info: www.motorrad-schrauberkurse.de

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