Driver Vehicle Standards Agency
1.1.1. Brake lever and pedal pivot in use
| Defect | Category |
|---|---|
| (a) Lever or pedal pivot too tight | Major |
| (b) Lever or pedal pivot has excessive wear or free play | Major |
1.1.2. Brake lever and pedal condition and travel
A motorcycle must only be failed for insufficient reserve travel if the brake lever is touching the handlebar or the brake pedal is fouling another part of the motorcycle. Motorcycles with servo-assisted braking systems should be checked with the engine running.
On some motorcycles it may be possible to pull the brake lever back until it touches the handlebar. In such cases the extent of reserve travel should be assessed during the brake test.
A brake pedal should be failed if its grooves or raised sections are worn smooth. However, a brake pedal should not be failed if the motorcycle has been manufactured with one that does not have grooves or is fitted with anti-slip material.
Where a brake pedal rubber is fitted, this is considered an anti-slip material. Its therefore not regarded as a defect if the design pattern is worn smooth.
| Defect | Category |
|---|---|
| (a)Brake control has insufficient reserve travel | Major |
| (b) Brake control: (i) not releasing correctly (ii) not releasing correctly so that the functionality of brakes affected | Minor Major |
| (c) Brake pedal anti-slip provision missing, loose or worn smooth | Major |
| (d) Brake control so positioned, bent or shortened that the brake cannot be readily applied | Major |
| (e) Brake control: (i) insecure (ii) so insecure that the brake cannot be readily applied | Major Dangerous |
1.1.3. Not in use
1.1.4. Not in use
1.1.5. Not in use
1.1.6. Not in use
1.1.7. Not in use
1.1.8. Not in use
1.1.9. Not in use
1.1.10. Brake master cylinder and servo
To check the operation of the brake servo:
Apply the brake control with the ignition off.
With the brake still applied, turn the ignition on.
The inspection is successful when you feel that the brake control increases brake pressure without any increase in effort.
Hydraulic brake fluid level checks are confined to transparent reservoirs or where an indicator is fitted. Reservoir caps should not be removed.
| Defect | Category |
|---|---|
| (a) Brake servo: (i) defective or ineffective (ii) inoperative | Major Dangerous |
| (b) Master cylinder: (i) defective but brake still operating (ii) leaking | Major Dangerous |
| (c) Master cylinder insecure | Major |
| (d) Brake fluid: (i) below minimum mark (ii) significantly below minimum mark (iii) not visible | Minor Major Dangerous |
| (e) Master cylinder reservoir cap missing | Major |
1.1.11. Rigid brake pipes
If the corroded metal brake pipes have surface dirt that needs to be removed before its possible to assess their condition, its permissible to lightly scrape the pipe with a specialist brake pipe corrosion tool or the corrosion assessment tool spade end. It must be done with care so that any protective coating does not get damaged.
Chafing, corrosion or damage to a rigid brake pipe so that its wall thickness is reduced by 1/3 (approximately 0.25mm for typical hydraulic brake pipe) justifies rejection, although its accepted that this is not easy to determine. The wall of a typical hydraulic brake pipe is around 0.75mm thick. If you are not sure whether the pipe is sufficiently deteriorated to justify rejection, you should give the benefit of the doubt.
| Defect | Category |
|---|---|
| (a) Brake pipe is at imminent risk of failure or fracture | Dangerous |
| (b) Leaking brake pipe or connection | Dangerous |
| (c) Brake pipe excessively damaged or excessively corroded | Major |
| (d) Brake pipe: (i) inadequately clipped or supported (ii) likely to become detached or damaged | Minor Major |
1.1.12. Flexible brake hoses
A hose should only be considered excessively damaged or chafed if its severe enough to expose the reinforcement.
| Defect | Category |
|---|---|
| (a) Brake hose damaged and likely to fail | Dangerous |
| (b) Flexible brake hose: (i) slightly damaged, chafed or twisted (ii) excessively damaged, deteriorated, chafed, twisted or stretched | Minor Major |
| (c) Brake hoses or connections leaking | Dangerous |
| (d) Brake hose bulging under pressure | Major |
| (e) Brake hose porous | Major |
| (f) Brake hose ferrules: (i) excessively corroded (ii) excessively corroded and likely to fail | Major Dangerous |
1.1.13. Brake linings and pads
| Defect | Category |
|---|---|
| (a) Brake lining or pad worn below 1.0mm | Dangerous |
| (b) Brake lining or pad contaminated with oil, grease etc. | Major |
| (c) Brake lining or pad missing or incorrectly mounted | Dangerous |
1.1.14. Brake discs and drums
A brake disc or drum must be significantly worn before rejection is justified. Being worn below the manufacturers recommended limit is not a reason in itself.
| Defect | Category |
|---|---|
| (a) Brake disc or drum: (i) significantly and obviously worn (ii) insecure, fractured or otherwise likely to fail | Major Dangerous |
| (b) Contaminated with oil, grease etc. | Major |
| (c) Missing | Dangerous |
| (d) Brake drum back plate insecure | Major |
1.1.15. Brake cables, rods, levers and linkages
A component such as a brake rod should be considered to be excessively worn or corroded if its diameter is reduced by more than a third.
| Defect | Category |
|---|---|
| (a) Cable damaged or knotted | Major |
| (b) Component excessively worn or corroded | Major |
| (c) Cable, rod or joint insecure | Major |
| (d) Cable guide defective affecting operation | Major |
| (e) Restriction in free movement of the braking system | Major |
| (f) Abnormal movement of levers indicating maladjustment or excessive wear | Major |
1.1.16. Brake callipers and cylinders
| Defect | Category |
|---|---|
| (a)Brake calliper or cylinder cracked or damaged and: (i) braking performance not affected (ii) braking performance affected | Major Dangerous |
| (b) Brake calliper or cylinder leaking and: (i) braking performance not affected (ii) braking performance affected | Major Dangerous |
| (c) Brake calliper or cylinder insecure or inadequately mounted and: (i) braking performance not affected (ii) braking performance affected | Major Dangerous |
| (d) Brake calliper or cylinder: (i) excessively corroded (ii) excessively corroded and likely to crack |