Motor Vehicle System and Traffic Routing Technique Test Laboratory Motor Vehicle Engineering Study on Anti Tampering Devices relating to Two or Three Wheeled Motor Vehicles by order of the Commission of the European Communities Contract No. FIF. 20020691 - Final Report - Hannover, December the 18th, 2003 Project Team Project Responsibility Project Management Klaus Baumeister Marcus Berg Thomas Braun Stephan Hartmann Markus Leiber Klaus Dittmar Michael Melz Dr. Horst Safarovic Motor Vehicle System and Traffic Routing Technique Test Laboratory Motor Vehicle Engineering Test Laboratory Motor Vehicle Engineering, accredited according to DIN EN ISO / IEC 17025 and DIN EN 45001 by the Accreditation Body of the German Federal Motor Vehicle Registration Agency (KBA) under DAR-Register-No.: KBA-P 00004-96 TÜV NORD STRASSENVERKEHR GMBH & Co. KG • Am TÜV 1 • 30519 Hannover Telefon 0511 986-1598 Geschäftsführer: HRB Hannover Nr. 56596 Postbank Hannover (BLZ 250 100 30) 60 89 02-301 Fax 0511 986-1998 Dipl.-Ing. Volker Drube Ust. IdNr.: DE 812322562 Deutsche Bank AG, Hannover (BLZ 250 700 70) 60 03 38 E-mail: [email protected] Vorsitzender des Aufsichtsrates: Dresdner Bank AG, Hannover (BLZ 250 800 20) 1 11 04 45 00 http://www.tuev-nord.de/398.asp Dr. rer. nat. Klaus-D. Röker Motor Vehicle System Project Anti Tampering Devices and Traffic Routing Technique Test Laboratory Motor Vehicle Engineering Table of Contents Page 0 Tabel of Contents 1 - 4 1 Background and scope of work 5 - 6 2 Results of the Project 7 - 78 2.0 General 7 2.0.1 Project handling 7 2.0.2 General remarks about the procurement of information 9 2.0.3 Evaluation of statistics to limit the scope of project work 12 2.1 Review of the role and function of anti-tampering devices in two- or three-wheeled motor vehicles 22 2.1.1 Description of the Goals and Technical Possibilities of such Manipulations to two-or three-wheeled motor vehicles 22 2.1.1.1 General 22 2.1.1.2 Technical Possibilities and Aims of the Manipulation 28 2.1.1.3 Effort, Efficiency and Consequences of Manipulations 29 2.1.1.4 Remarks to the different legislative regulations in the member states of the European Union 32 2.1.1.5 Literature-study on Technical Possibilities and Aims of the Manipulation 36 0_Table_of_Contents.doc page 1 of 81 Motor Vehicle System Project Anti Tampering Devices and Traffic Routing Technique Test Laboratory Motor Vehicle Engineering Table of Contents Page 2.1.2 Results of the Questionnaires to Manufacturers and Manufacturer’s organisations 39 2.1.2.1 Returns from the questionnaires of the vehicle manufacturers 39 2.1.2.2 Results based on the questionnaire of the manufacturers 40 2.1.3 Analysis by technical experts of the strong and weak points of the different systems aimed against unauthorised manipulation 43 2.2 The effective contribution made by anti-tampering measures in terms of speed, noise and gaseous emissions reductions, since the multi-directive 97/24/EC came into force 45 2.2.1 Results of the Questionnaires to dealers of tuning kits 45 2.2.2 Results of Questions to further Institutions 48 2.2.2.1 Approval Authorities and Technical Services 48 2.2.2.2 Inspection Organisations 49 2.2.2.3 Others 52 2.2.3 Examples for the Technical Realisation of Manipulations 55 2.2.3.1 Increased power by Removal of the Throttle Stop 55 2.2.3.2 Alteration of noise emissions by de-tuning of the silencer 57 2.2.3.3 Alteration of the transient response of a carburettor 58 2.2.3.4 Alteration of the Engine Control Unit by manipulation of the gear-sensor 59 2.2.3.5 Alteration of the Engine Control Unit by adding Electronic Components 61 0_Table_of_Contents.doc page 2 of 81 Motor Vehicle System Project Anti Tampering Devices and Traffic Routing Technique Test Laboratory Motor Vehicle Engineering Table of Contents Page 2.2.3.6 Alteration of the engine control by replacement or manipulation of the ECU 62 2.2.4 Summary: Assessment of the efficiency of the existing legislation 64 2.3 Recommendations concerning the scope, extent and content of possible amendments to directive 97/24/EC, chapter 7 and further directives 69 2.3.1 Requirements for alterations of the directive 97/24/EC, chapter 7 (Anti-manipulation) 69 2.3.2 Requirements for alterations of the directive 97/24/EC, chapter 9 (noise-level) 71 2.3.3 Requirements for alterations of the directive 96/96/EC (periodic technical inspection) 73 2.3.4 Requirements for alterations of the directive 2002/24/EG (Type-approval for 2- and 3-wheeled motorised vehicles) 75 3 Summery 79 – 81 4 Appendix A1 Table of Acronyms 2 pages A2 Possibilities, Aims and Reasons for the Manipulation 4 Pages A3 Effort, Efficiency and Consequences of Manipulations 24 Pages A4 Ownership tax [2] (10.3 , 10.3.1) 2 pages A5 Annual Insurance Cost [2] (8.1, 8.1.1 - 8.1.9) 6 pages A6 PTW Riding Access [2] (11, 12, 12.1) 3 pages A7 Roadworthiness test [2] (9.3) 1 page A8 List of EU-directives considered in the study 1 page 0_Table_of_Contents.doc page 3 of 81 Motor Vehicle System Project Anti Tampering Devices and Traffic Routing Technique Test Laboratory Motor Vehicle Engineering Table of Contents Page A9 Description and analysis of the different technical systems/measures against unauthorised manipulation 44 pages A10 Analysis of the questionnaires to dealers of tuning-parts 3 pages A11 Statistics concerning faults found at Technical Inspections (TI) of motorcycles carried out by TÜV NORD STRASSENVERKEHR GmbH 1 page A12 Recommendation for the alteration of directive 97/24/EC, chapter 7 27 pages A13 Questions to Vehicle Manufacturers concerning Systems/Measures against Manipulation (unauthorised tampering) 17 pages A14 Questions to dealers of tuning-parts about systems / measures against unauthorized manipulation 7 pages A15 Example of a covering letter to vehicle manufacturer / dealer of tuning parts 1 page A16 Example of a covering letter to further relevant institutions 1 page A17 Writing of the European Commission 002538 from 10.03.2003 2 pages A18 List of Vehicle Manufacturers 4 pages A19 List of Dealers of Tuning-Parts 5 pages A20 List of Approval Authorities 7 pages A21 List of Technical Services 14 pages A22 Research Type Approvals 29 pages A23 Project schedule 4 pages A24 Bibliography 1 page 0_Table_of_Contents.doc page 4 of 81 Motor Vehicle System Project Anti Tampering Devices and Traffic Routing Technique Test Laboratory Motor Vehicle Engineering Background and scope of work 1 Background and scope of work The EC legislative type-approval framework, established by Directive 92/61/EEC (motorcycles), provides for the type-approval of whole vehicles or components, technical systems and units. The framework directive 92/61/EEC and the series of separate directives subsequently enacted there-under, establishes the various construction, design and performance requirements which need to be fulfilled before new; two-or three-wheeled motor vehicles can be type-approved. Type-approval constitutes a fundamental pre- requisite of vehicle sale, registration or it's entry into service. The type-approval requirements relating to anti-tampering measures are laid down in Chapter 7 of Directive 97/24/EC of the European Parliament and of the Council of 17 June 1997 on certain components and characteristics of two- or three-wheel motor vehicles. Furthermore Article 2 of Directive 97/24/EC stipulates that the Commission shall carry out a detailed study in order to ascertain whether or not the anti-tampering measures in force can be considered appropriate, inadequate or too extreme in the light of intended aims. The Commission of the EU wishes to ensure that the current legislation in relation to anti- tampering measures, responds effectively to the requirements of the interested parties. The Commission considers that interested parties can be presumed to include: • vehicle and component manufacturers (including their representative organisations); • national type-approval authorities that certify the acceptability of products before they are sold on the open market and officially registered; • national transport/highway authorities responsible for vehicle inspection and thereby ensuring proper compliance with in-use conformity rules; • vehicle purchasers who require the product to fulfil their legitimate expectations in terms of quality, performance and safety; • other road users who expect that products used on the road respond properly to safety and environmental requirements; • the general public and organisations representing the public interests of environmental protection and road safety. 1_Background_and_scope_of_work.doc page 5 of 81 Motor Vehicle System Project Anti Tampering Devices and Traffic Routing Technique Test Laboratory Motor Vehicle Engineering Background and scope of work Commission services wish to examine the relevance and effectiveness of the separate directives presently regulating the design, performance, construction and fitting of anti- tampering measures. This examination is required in order to assess the precise scope and natures of on-going technological advance, and to ensure that any future regulatory changes take due account of the paramount need for safety for vehicle occupants and other road users. This results in the range of the project, focusing generally on three areas: • Review of the role and function of anti-tampering devices on two- or three-wheeled motor vehicles • The effective contribution made by anti-tampering measures in terms of speed, noise and gaseous emissions reductions since the multi-directive 97/24/EC came into force • Recommendations concerning the scope, extent and content of possible amendments to Directive 97/24/EC The existing type approval directive 92/61/EEC will be cancelled on November 9th, 2003 and replaced by the directive 2002/24/EC of the European parliament and the council, dated March 18th, 2002.