PART 1512—REQUIREMENTS FOR BICYCLES Authority: Secs. 2(f)(1)(D), (q)(1)(A), (s), 3(e)(1), 74 Stat. 372, 374, 375, as amended, 80 Stat. 1304-05, 83 Stat. 187-89 (15 U.S.C. 1261, 1262); Pub. L. 107-319, 116 Stat. 2776. Source: 43 FR 60034, Dec. 22, 1978, unless otherwise noted. Subpart A—Regulations § 1512.1 Scope. This part sets forth the requirements for a bicycle as defined in § 1512.2(a) (except a bicycle that is a “track bicycle” or a “one-of-a-kind bicycle” as defined in § 1512.2 (d) and (e)) which is not a banned article under § 1500.18(a)(12) of this chapter. § 1512.2 Definitions. For the purposes of this part: (a) Bicycle means: (1) A two-wheeled vehicle having a rear drive wheel that is solely human-powered; (2) A two- or three-wheeled vehicle with fully operable pedals and an electric motor of less than 750 watts (1 h.p.), whose maximum speed on a paved level surface, when powered solely by such a motor while ridden by an operator who weighs 170 pounds, is less than 20 mph. (b) Sidewalk bicycle (c) Seat height (d) Track bicycle (e) One-of-a-kind bicycle (f) Normal riding position (g) Recumbent bicycle [43 FR 60034, Dec. 22, 1978, as amended at 68 FR 7073, Feb. 12, 2003; 76 FR 27888, May 13, 2011] § 1512.3 Requirements in general. Any bicycle subject to the regulations in this part shall meet the requirements of this part in the condition to which it is offered for sale to consumers; any bicycle offered for sale to consumers in disassembled or partially assembled condition shall meet these requirements after assembly according to the manufacturer's instructions. For the purpose of compliance with this part, where the metric and English units are not equal due to the conversion process the less stringent requirement will prevail. § 1512.4 Mechanical requirements. (a) Assembly. (b) Sharp edges. (c) Integrity. (d) Attachment hardware. 1 2 1 2 (e)-(f) [Reserved] (g) Excluded area. 1/2 1/4 3/16 (h) [Reserved] (i) Control cable ends. (j) Control cable abrasion. [43 FR 60034, Dec. 22, 1978, as amended at 76 FR 27888, May 13, 2011] § 1512.5 Requirements for braking system. (a) Braking system. (b) Handbrakes. (1) Stopping distance. (2) Hand lever access. (3) Grip dimension. 1/2 1/2 1/2 (4) Attachment. (5) Operating force. (6) Pad and pad holders. (7) [Reserved] (8) Hand lever location. (9) Hand lever extensions. (c) Footbrakes. (1) Stopping distance. 3 3 (2) Operating force. (3) Crank differential. (4) Independent operation. (d) Footbrakes and handbrakes in combination. 3 (e) Sidewalk bicycles. (2) Sidewalk bicycles with a seat height of 560 mm (22 in) or greater (with seat height adjusted to its lowest position) shall be equipped with a footbrake meeting all the footbrake requirements of § 1512.5(c), including the specified tests except that the braking force transmitted to the rear wheel shall be in accordance with the sidewalk bicycle footbrake force tests, § 1512.18(f). (3) Sidewalk bicycles with a seat height less than 560 mm (22 in) (with seat height adjusted to its lowest position) and not equipped with a brake shall not have a freewheel feature. Such sidewalk bicycles equipped with a footbrake shall be tested for brake force in accordance with the sidewalk bicycle footbrake force test, § 1512.18(f). Such sidewalk bicycles not equipped with brakes shall be identified with a permanent label clearly visible from a distance of 3.1 m (10 ft) in daylight conditions and promotional display material and shipping cartons shall prominently display the words “No Brakes.” § 1512.6 Requirements for steering system. (a) Handlebar stem insertion mark. 1/2 (b) Handlebar stem strength. (c) Handlebar. (d) Handlebar ends. (e) Handlebar and clamps. [43 FR 60034, Dec. 22, 1978, as amended at 76 FR 27888, May 13, 2011] § 1512.7 Requirements for pedals. (a) Construction. (b) Toe clips. (c) Pedal reflectors. § 1512.8 Requirements for drive chain. The drive chain shall operate over the sprockets without catching or binding. The tensile stength of the drive chain shall be no less than 8010 N (1,800 lbf) or 6230 N (1,400 lbf) for sidewalk bicycles. § 1512.9 Requirements for protective guards. (a) Chain guard. 3/8 (b) Derailleur guard. § 1512.10 Requirements for tires. The manufacturer's recommended inflation pressure shall be molded into or onto the sidewall of the tire in lettering no less than 3.2 mm ( 1/8 § 1512.11 Requirements for wheels. (a) Spokes. (b) Alignment. 1/16 (c) Rims. § 1512.12 Requirements for wheel hubs. All bicycles (other than sidewalk bicycles) shall meet the following requirements: (a) Locking devices. (1) Rear wheels. (2) Front wheels. (b) Quick-release devices. (c) Front hubs. [43 FR 60034, Dec. 22, 1978, as amended at 76 FR 27888, May 13, 2011] § 1512.13 Requirements for front fork. The front fork shall be tested for strength by application of at least 39.5 J (350 in-lb) of energy in accordance with the fork test, § 1512.18(k)(1), without visible evidence of fracture. Sidewalk bicycles need not meet this requirement. § 1512.14 Requirements for fork and frame assembly. The fork and frame assembly shall be tested for strength by application of a load of 890 N (200 lbf) or at least 39.5 J (350 in-lb) of energy, whichever results in the greater force, in accordance with the frame test, § 1512.18(k)(2), without visible evidence of fracture or frame deformation that significantly limits the steering angle over which the wheel can be turned. Sidewalk bicycles are exempt from this section. § 1512.15 Requirements for seat. (a) Seat limitations. (b) Seat post. (c) Adjustment clamps. [43 FR 60034, Dec. 22, 1978, as amended at 76 FR 27888, May 13, 2011] § 1512.16 Requirements for reflectors. Bicycles shall be equipped with reflective devices to permit recognition and identification under illumination from motor vehicle headlamps. The use of reflector combinations off the center plane of the bicycle (defined in § 1512.18(m)(2)) is acceptable if each reflector meets the requirements of this section and of § 1512.18 (m) and (n) and the combination of reflectors has a clear field of view of ±10° vertically and ±50° horizontally. Sidewalk bicycles are not required to have reflectors. (a) Front, rear, and pedal reflectors. (b) Side reflectors. (c) Front reflector. (d) Rear reflector. (e) Pedal reflectors. (f) Side reflectors. (g) Reflector tests. (h) Retroreflective tire sidewalls. (1) The retroreflective material shall form a continuous circle on the sidewall. (2) The retroreflective material shall adhere to the tire such that after the tire has been subjected to a temperature of 50° ±3 °C (122° ±5.4 °F) for 30 minutes, the retroreflective material cannot be peeled or scraped away without removal of tire material. (3) The retroreflective material shall be as resistant to abrasion as is the adjacent sidewall material so that when retroreflective material is removed from the inflated tire by abrasion with a wet, steel bristle brush, tire material will be removed along with the retroreflective material. (4) The retroreflective material shall be tested for performance in accordance with the retroreflective tire test, § 1512.18(o), to assure the reflectance properties over the angles given in table 3. When a portion of the retroreflective material is selected (and the remainder is masked as specified in § 1512.18(o)(2)(i)), the selected portion shall not contact the ground plane when the assembled bicycle is resting on that plane in any orientation. (i) Retroreflective rims. (1) The retroreflective material shall form a continuous circle on the rim. (2) If the retroreflective material is applied to the rim in the form of a self-adhesive tape, the following requirement must be met: Use a sharp knife, razor blade, or similar instrument to carefully release an end of the tape material sufficient to be grasped between the thumb and finger. Grasp the freed tape end and gradually pull in a direction 90° to the plane of the rim. The tape material must break before additional separation (peeling) from the rim is observed. (3) After the retroreflective material is abraded in accordance with the abrasion test for retroreflective rims at § 1512.18(r), the rim must then be tested for performance in accordance with the retroreflective tire and rim test at § 1512.18(o), to assure the reflectance properties over the angles given in table 3. [43 FR 60034, Dec. 22, 1978, as amended at 45 FR 82627, 82628, Dec. 16, 1980] § 1512.17 Other requirements. (a) Road test. (b) Sidewalk bicycle proof test. (c) Ground clearance. (d) Toe clearance. 1/2 § 1512.18 Tests and test procedures. (a) Sharp edge test. (b) [Reserved] (c) Protective cap and end-mounted devices test. (d) Handbrake loading and performance test: (1) Apparatus. (2) Procedure. (i) Loading test procedure. 4 4 (ii) Loading test criteria. (iii) Rocking test procedure. 4 (iv) Rocking test criteria. (v) Performance test procedure. (A) The bicycle shall be ridden over a dry, clean, smooth paved test course free from protruding aggregate. The test course shall provide a coefficient of friction of less then 1.0 and shall have a slope of less than 1 percent. (B) The wind velocity shall be less than 11 km/h (7 mph). (C) Only the brake system under test shall be actuated. (D) The bicycle shall attain the specified ground speed while the rider is in the normal riding position. (E) The rider shall remain in the normal riding position throughout the test. (F) The bicycle must be moving in a straight line at the start of brake application. (G) Corrections for velocity at the initiation of braking may be made. The corrected braking distance shall be computed as follow: S c V s m 2 S m where: S c V s V m S m The test run is invalid if at the commencement of the test, the measured test speed of the bicycle is not less than nor greater than the test speed required by this part 1512 by 1.5 km/h (0.9 mph). (H) Four test runs are required. The stopping distance shall be determined by averaging the results of the four test runs. (I) The stopping distances specified are based on a rider weight of at least 68.1 kg (150 lb) and a maximum rider and weight combination of 91 kg (200 lb). Greater stopping distances are allowable for heavier riders and test equipment weights at the rate of 0.30 m per 4.5 kg (1.0 ft per 10 lb). (J) A test run is invalid if front-wheel lockup occurs. (vi) Performance test criteria. 3 3 (e) Footbrake force and performance test. (1) Apparatus. (2) Force test. (3) Performance test. 3 Note: No allowance shall be made for rider weight. See § 1512.5(d) for additional requirements for bicycles with both handbrakes and footbrakes. (f) Sidewalk bicycle footbrake force test. (g) Handlebar stem test. (1) Procedure. (2) Criteria. (h) Handlebar test. (1) Stem-to-fork clamp test Procedure. (ii) Criteria. (2) Handlebar strength and clamp test Procedure. (ii) Criteria. (i) Pedal slip test. (j) Rim test. (1) Procedure. (2) Criteria. (3) Front hub retention test. (i) Procedures. (ii) Criteria. (k) Fork and frame test. (1) Fork test Procedure. (ii) Criteria. 1/2 (2) Fork and frame assembly test Procedure. (ii) Criteria. (l) Seat adjustment clamps and load test. (1) Procedure. (2) Criteria. (m) Reflector mount and alignment test. (1) Procedure. (2) Criteria. During test: (ii) Post test: (n) Reflector test. (1) Conditioning. (i) Warpage conditioning. (ii) Mechanical impact conditioning. 1/2 (iii) Moisture conditioning. 2 3/4 (2) Reflector performance test. D (ii) The observation angle is the angle formed by a line from the point of observation to the center of the reflector with a second line from the center of the reflector to the source of illumination. The entrance angle is the angle between the optical axis of the reflector and a line from the center of the reflector to the source of illumination. The entrance angle shall be designated left, right, up, and down in accordance with the position of the source of illumination with respect to the axis of the reflector as viewed from behind the reflector when the plane of the observation angle is vertical and the receiver is above the source. (iii) Photometric measurements shall be made either visually or photoelectrically. With either method, the light reflected to the observation point shall be determined. Also, the illumination on the reflector from the source shall be measured. (iv) For visual measurements a comparison lamp, emitting light similar in spectral quality to the reflector, shall be located adjacent to the reflector (at an angle not to exceed 1/2 1/2 1/2 (v) Reflectors that mount on the bicycle in a fixed rotational position with respect to the bicycle, or the bicycle component on which they are mounted (such as pedals or spokes), shall be tested with a single orientation. Reflectors that do not mount on the bicycle in a fixed rotational position with respect to the bicycle shall be rotated about their axis through 360° to find the minimum candlepower per footcandle for each test point. If the measurement falls below the minimum requirement at any test point, the reflector shall be rotated ±5° about its axis from the angle where the minimum occurs, and the maximum candlepower per footcandle within this angle shall be the measured value. (vi) Should uncolored reflections from the front surface interfere with photometric readings at any test point the lowest reading and location within 1° above, below, right, and left of the test point shall meet the minimum requirement for the test point. (vii) A recommended coordinate system for definition of color is the “Internationale de l'Eclairage (CIE 1931)” system. In the coordinate system and when illuminated by the source defined in table 4 of this part 1512, a reflector will be considered to be red if its color falls within the region bounded by the red spectrum locus and the lines y = 0.980−x and y = 0.335; a reflector will be considered to be amber if its color falls within the region bounded by the yellow spectrum locus and the lines y = 0.382, y = 0.790−0.667x, and y = x−0.120. (o) Reflective tire and rim test (Ref. § 1512.16(h) and (i)): (1) Apparatus. D D 10 10 D d D d (2) Procedure Masking. (ii) Orientation. (iii) Measurement. d r E. A A = [(E r s 2 Where: A = Ratio in meters, E r E s r d = The distance in meters from the receiver to the center of the wheel, r = The minimum radius in meters of the boundary circles of the retroreflective strip. The minimum value of A (iv) Criteria. A = 4Cos 2 3/2 where A is ratio in meters, θ is the entrance angle in degrees, and Φ is the observation angle in degrees. The criterion applies only for entrance angles from 0° to 40° and observation angles from 0.2° to 1.5°, and performance is not specified beyond this range. The values of A A (p) Road test. (1) Procedure. 1/2 1/2 (2) Criteria. (q) Sidewalk bicycle proof test. (1) Procedure. (r) Abrasion test for retroreflective rims. (1) This test consists of a steel wire cup brush rotating at a constant velocity of 60 rpm that is applied at a force of 2 N (0.45 lbf) to the retroreflective material on one side of a bicycle wheel rim. The rim is rotated about the axle at a linear velocity of 0.23 m/sec (9 in./sec). The test is complete when the wheel has completed 1000 revolutions. (2) Apparatus. (i) Test fixture. (ii) Abrader. (3) Specifications. (ii) The rotational velocity of the abrading brush shall be 60 rpm. (iii) The force normal to the plane of the retroreflective material at which the abrading brush is to be applied shall be 2 N (0.45 lbf). (iv) The bicycle wheel shall make 1000 complete revolutions per test. (v) The abrader shall be a cup brush having bristles that are 0.005 in. (approx. 0.13mm) diameter low carbon steel wire; an outside diameter of 0.5 inch (aprox. .13mm); a wire bristle length of 0.25 inch (approx. 6.4mm); and a cup diameter of 0.405 inch (approx. 10.29mm). 6 6 (vi) The abrasion test shall be conducted at an ambient temperature of between 16 °C (60 °F) and 27 °C (80 °F). (4) Procedure. (ii) Test the wheel in a suitable test fixture, according to the specifications in paragraph (r)(3) of this section. (iii) Clamp the wheel by its axle in the test fixture and align the axis of rotation so that the portion of the reflective material below the axis of the abrading brush is horizontal. (iv) Shape the cup brush by hand to the specified 0.5 (approx. 13mm) diameter. Any stray wire bristles projecting more than 1/32 (v) Adjust the rotational velocity of the bicycle wheel to obtain a linear velocity of 0.23 m/sec (9 in./sec) measured at the mid-point in the width of the retroreflective material. Adjust the force to obtain a force normal to the surface under the brush of 2 N (0.45 lbf). (vi) Apply the abrading brush to the retroreflective material on the wheel rim, and continue the test for 1000 complete revolutions of the bicycle wheel. [43 FR 60034, Dec. 22, 1978, as amended at 45 FR 82628, Dec. 16, 1980; 46 FR 3204, Jan. 14, 1981; 68 FR 52691, Sept. 5, 2003; 76 FR 27888, May 13, 2011] § 1512.19 Instructions and labeling. A bicycle shall have an instruction manual attached to its frame or included with the packaged unit. (a) The instruction manual shall include at least the following: (1) Operations and safety instructions describing operation of the brakes and gears, cautions concerning wet weather and night-time operation, and a guide for safe on-and-off road operation. (2) Assembly instructions for accomplishing complete and proper assembly. (3) Maintenance instructions for proper maintenance of brakes, control cables, bearing adjustments, wheel adjustments, lubrication, reflectors, tires and handlebar and seat adjustments; should the manufacturer determine that such maintenance is beyond the capability of the consumer, specifics regarding locations where such maintenance service can be obtained shall be included. (b) A bicycle less than fully assembled and fully adjusted shall have clearly displayed on any promotional display material and on the outside surface of the shipping carton the following: (1) A list of tools necessary to properly accomplish assembly and adjustment, (2) a drawing illustrating the minimum leg-length dimension of a rider and a method of measurement of this dimension. (c) The minimum leg-length dimension shall be readily understandable and shall be based on allowing no less than one inch of clearance between (1) the top tube of the bicycle and the ground plane and (2) the crotch measurement of the rider. A girl's style frame shall be specified in the same way using a corresponding boys' model as a basis. (d) [Reserved] (e) Every bicycle subject to the requirements of this part 1512 shall bear a marking or label that is securely affixed on or to the frame of the bicycle in such a manner that the marking or label cannot be removed without being defaced or destroyed. The marking or label shall identify the name of the manufacturer or private labeler and shall also bear some form of marking from which the manufacturer can identify the month and year of manufacture or from which the private labeler can identify the manufacturer and the month and year of manufacture. For purposes of this paragraph, the term manufacture [43 FR 60034, Dec. 22, 1978, as amended at 60 FR 62990, Dec. 8, 1995] § 1512.20 Separability. If any section or portion thereof of this part 1512 or its application to any person or circumstance is held invalid, the remainder of the section(s) and its (their) application to other persons or circumstances is not thereby affected. Subpart B—Policies and Interpretations [Reserved] Figure 1 to Part 1512—Bicycle Front Fork Cantilever Bending Test Rig Figures 2 and 3 to Part 1512—Handlebar Stem Loading and Entrance 8 Observation Angles Figure 5 to Part 1512—Typical Handbrake Actuator Showing Grip Dimension Figures 6 and 7 to Part 1512—Toe Clearance and Chain Guard Requirements Figure 8 to Part 1512—Reflectorized Bicycle Wheel Rim Abrasion Test Device Table 1 to Part 1512—Minimum Candlepower per Incident Foot-Candle for Clear Reflector 1 Observation angle Front, rear, and side reflectors; entrance angle in degrees Pedal reflectors; entrance angle in degrees 0 10 up/down 20 left/right 0 10 up/down 20 left/right 0.2 27.0 18.0 9.0 7.5 6.0 3.0 0.3 6.0 4.8 2.4 1.5 .28 .20 .12 .28 .20 .12 1 5 8 1 4 Table 2 to Part 1512—Minimum Candlepower per Incident Foot-Candle for Clear Reflector 1 Observation angle Front, rear, and side reflectors; entrance angle in degrees 30 left/right 40 left/right 50 left/right 0.2 8.0 7.0 6.0 1.5 .12 .12 .12 1 5 8 1 4 Table 3 to Part 1512—Minimum Acceptable Values for the Quantity A Defined in the Retroreflective Tire and Rim Test Procedure Observation angle (degrees) Entrance angle (degrees) Minimum acceptable value of A Meters Feet 0.2 −4 2.2 7.25 .2 20 1.9 6.27 .2 40 1.3 4.29 1.5 −4 .22 .73 1.5 20 .19 .63 1.5 40 .13 .43 [43 FR 60034, Dec. 22, 1978, as amended at 45 FR 82631, Dec. 16, 1980; 46 FR 3204, Jan. 14, 1981] Table 4 to Part 1512—Relative Energy Distribution of Sources Wave length (nanometers) Relative energy 380 9.79 390 12.09 400 14.71 410 17.68 420 21.00 430 24.67 440 28.70 450 33.09 460 37.82 470 42.87 480 48.25 490 53.91 500 59.86 510 66.06 520 72.50 530 79.13 540 85.95 550 92.91 560 100.00 570 107.18 580 114.44 590 121.73 600 129.04 610 136.34 620 143.62 630 150.83 640 157.98 650 165.03 660 171.96 670 178.77 680 185.43 690 191.93 700 198.26 710 204.41 720 210.36 730 216.12 740 221.66 750 227.00 760 232.11