540 CMR 4.00

4.06 Procedures for Inspection of Motorcycles

(1) Prior to beginning inspection. A visual check of the motorcycle shall be made to determine that under-inflated tires, condition of suspension and other conditions visible to the inspector will not impede or interfere with the proper aiming of headlamps. In order to proceed with inspection, a properly functioning side stand or center stand must be able to support the weight of the motorcycle while wheels, front end and swing arm are examined. Passenger foot rests should be put in an upright stored position, if possible, to prevent interference with the inspection.

(2) Inspection of the motorcycle. 540 CMR 4.06 shall apply to two wheeled motorcycles or two wheeled motorcycles with a side car. All inspections must be performed in accordance with the applicable provisions of 540 CMR 4.00 by certified inspectors in the approved inspection bay only. Inspectors must first collect the proper fee and secure the proper Certificate of Registration, except for motorcycles submitted for inspection displaying temporary plates, dealer plates (as defined in 540 CMR 4.02) or motorcycles that are in the process of the seven day transfer of registration (under the provisions of M.G.L. c. 90, § 2). The following inspection shall then be completed:

(a) The number plate must be undamaged, securely mounted on the rear of the motorcycle, clean and clearly visible. No accessory mounted on the motorcycle may interfere with a clear view of the number plate. Any decorative number plate or number plate replica not issued by the Registry of Motor Vehicles for the motorcycle being inspected on which appears the word "Massachusetts" must be removed from the motorcycle.

(b) A Certificate of Rejection shall be issued, after inspection is completed, for any of the following:

1. expired registration,

2. registration number and number plate do not match,

3. description of motorcycle does not fit the motorcycle,

4. vehicle identification numbers on the motorcycle have been removed, altered, or are illegible, or if any of the characters on the vehicle identification plate do not correspond with the Registration Certificate.

(c) A Vehicle Identification Number Correction Form must be given to the operator of any motorcycle rejected due to the identification or registration number.

(3) Brakes.

(a) Brakes must be adequate to stop a motorcycle from a speed of 20 m.p.h. in not more than 19 feet. Each motorcycle shall have either a split service brake system or two independently actuated service brake systems which, upon application, act on front and rear wheels. Any motorcycle which has a number plate issued under the provisions M.G.L. c. 90, § 6A (Plates for antique motor cars) which was not manufactured with either a split service brake system or two independently actuated service brake systems shall be required to have one brake system adequate to stop said motorcycle within the aforementioned distances. For more recent model motorcycles observe whether the motorcycle utilizes a brake anti-lock equalizer system which proportionately controls braking pressure to the front and rear wheels.

(b) Mechanical Brake System. Inspect the linkage, cables, pivots and bearings for high friction, wear and broken or missing parts. Reject motorcycle if:

1. Brake adjustment changes under any steering or loading.

2. Cotter pins are missing.

3. Pins or clevises are worn more than 25% of the original diameter.

4. The cam operating lever has been repositioned on the shaft as a means of avoiding replacement of worn cam, shoes or lining.

5. Any cables are frayed (two or more broken strands).

6. Any brake adjustment mechanism which will not maintain an adjusted position or is adjusted to its maximum extent.

7. Front brake cable is routed so as to be pinched between fork and frame.

8. There is any roughness, binding, or jamming in levers or pedals.

9. Less than 1/3 reserve remains in hand or foot brake when brakes are applied.

10. Modifications make the pedal or lever inaccessible for adequate leverage or operation.

11. Any portion of the brake hand lever is broken or missing.

(c) Hydraulic Brake System. Visually inspect the condition of the hydraulic system. Note: Do Not Remove Wheels. Reject the motorcycle if:

1. Hoses or tubing leaks or they are cracked, chafed, flattened, restricted or are improperly fastened.

2. Master cylinder leaks or the reservoir capacity is less than the manufacturer's recommended safe level if known or less than 1/2 total capacity.

3. There is any leakage in the brake system.
4. The push rod is improperly adjusted.

5. Wheel cylinder or caliper leaks or fails to function.

(d) Hydraulic System Tests. Test motorcycle in a standing position. The inspector should be able to maintain brake or hand lever reserve under moderate force (40-60 lbs.) for 15 seconds. Reject the motorcycle if brake reserve cannot be maintained for 15 seconds or if there is less than approximately 1/3 of the total available pedal or brake lever travel remains. The brake lever and pedal should exhibit smooth, firm and responsive action.

Allow wheels to turn freely when not in the braking mode. Reject the motorcycle if binding occurs and wheels do not turn freely.

(e) Visual Inspection of Brake Pads and Discs. Where pads and discs are visible check and reject if:

1. There is any substantial crack extending to the edge of the disc or pad.

2. There is evidence of mechanical damage other than wear.

3. Friction surface of disc or pad is contaminated with oil, grease or brake fluid.

4. There is excessive roughness to the disc.

5. The disc is warped or bent.

6. Pad is broken, loose or worn beyond replacement indicators.

(4) Muffler and Exhaust System.

(a) The motorcycle shall be equipped with a muffler to prevent excessive and unnecessary noise which is in good working order and in constant operation. Accelerate motor to half throttle position to test for unnecessary noise and emission of any unreasonable amount of smoke. Reject a motorcycle which has a muffler cut-out or by-pass of the baffle plates, screens or other original internal parts have been removed and not replaced. Unnecessary noise is herein defined as any noise which is louder than that emitted by the motorcycle with original manufacturers muffler and exhaust system equipment.

(b) The exhaust system includes the exhaust manifold, the piping leading from the flange at the exhaust manifold to and including the muffler and tail piping. Visually and audibly inspect the exhaust system and reject the motorcycle if:

1. Tail pipe end is pinched or obstructed.

2. System components are not securely fastened with proper clamps or hangers.

3. The exhaust system is not shielded to prevent riders from being burnt while riding in normal seated position.

(5) Steering, Alignment, and Suspension of Front End.

(a) Wheel axle bearings. Place motorcycle on motorcycle accessory lift or center stand and slowly spin the wheels. Reject the motorcycle if:

1. There is noticeable play or roughness when wheel is rotated or a growl is heard when wheel is rotated.

2. Wheel bearing seals are cracked, torn, cut or are discolored a reddish-brown color.

(b) Wheel run-out and alignment. Inspect front to rear wheel alignment, front wheel to fork tube alignment and wheel run-out. Reject motorcycle if:

1. Front to rear wheel misalignment exceeds one inch.

2. Front wheel is not vertical and parallel to front fork tubes.

3. Front fork tubes are bent or damaged preventing full travel and free action of front forks.

4. Wheel (rim) run-out is greater than manufacturer's suggested serviceable limit or, if unavailable, greater than .060".

(c) Steering head bearing or bushings. With front wheel slightly off the ground, turn handlebars side to side. Reject motorcycle if front fork binds.

(d) Front fork tube suspension. Inspect and reject if:

1. Front fork suspension has been removed and replace with a solid connection.

2. There is severe leakage (not slight dampness) of front fork tube seal.

3. Dampening effect is diminished indicating loss of shock absorber function.

(e) Handlebars. Inspect handlebars and reject if:

1. Handlebars or grips are higher than operator's shoulder level when properly seated upon motorcycle.

2. Handlebars are not of sturdy construction or if of lightweight bicycle quality.

3. Handlebars do not provide a minimum of 18 inches between grip ends.

4. Handlebars are not equipped with grips of non-slip design and material.

5. Handlebars prevent front fork from rotating from stop to stop.

6. Handlebars are cracked or deformed.

7. Handlebars are improperly aligned with front wheel.

8. Handlebars are not securely fixed, however, rubber mounted handlebars may have slight movement.

9. Handlebars that have been modified or repaired in an unsafe manner.

(6) Horn. Sound horn and test for adequate signal. The horn must be securely fastened to the motorcycle and shall not require removal of the operator's hand from the handlebar for use. The horn shall be distinctly audible at a distance of 200 feet under normal atmospheric conditions. The horn shall have a steady, non-oscillating tone which shall sound only during the time the activating switch is manually applied. The horn shall not be unreasonably loud or harsh.

(7) Windshield or Windscreen. Windshield or windscreen are not required, but if installed, they shall be free of cracks, discoloration or scratches which would create any vision obstruction and they shall have no sharp edges. Only approved plexi-glass is permitted. No sign, poster, decal, other non-transparent material or mounting hardware shall be allowed on a windshield or windscreen which would obstruct the vision of the operator.

(8) Tires. Only pneumatic rubber tires shall be permitted. Inspect tires and reject motorcycle if:

(a) There is a fabric break or cut, bulge, bump or knot related to the deterioration of the tire structure.

(b) There is any ply or cord structure visible.

(c) There is less than 2/32" of tread depth-measured in a major tread grove nearest the tire center using a tire tread depth gauge.

(d) Tire is worn so that a tread wear indicator contacts the road surface in any two adjacent groves.

(e) Tire has been repaired with a sidewall plug or patch. Tire tube, if known, has been patched.

(g) There is any combination of radial ply tire with non-radial tire, unless approved by tire or motorcycle manufacturer.

(h) Tires designated as front or rear only are improperly mounted or tires with directional arrow indication are mounted with arrow in improper rotating direction.

(i) Tire is not type approved by the Department of Transportation and/or does not have a "D.O.T." designation on the sidewall, or is labeled "Not For Highway Use," "For Racing Purposes Only" or displays other similar marking (except for farm vehicles, implements of husbandry, and if off-road equipment is used on highway at restricted speeds).

(j) Tire is obviously under or over-inflated.

(k) Tire is smaller than manufacturer's specified minimum or a size that causes tire to contact with the body or chassis.

(l) There are rusted or rotted valve stems.

(m) A tube type tire is used in a tubeless application.

Procedures for Inspection of Motorcycles (continued)