The DVSA has updated the HGV and PSV Inspection Manuals, and every transport operator needs to understand what has changed. These manuals guide how vehicles are inspected at the MOT, during roadside checks, and during maintenance inspections.
Even small updates can affect pass rates, maintenance planning, and your Operator Licence compliance. This guide explains the key changes in simple terms and shows how Blue Flag Transport Consulting helps operators adjust without disruption.
Why These Updates Matter
The inspection manuals define the standards used to judge roadworthiness. When the DVSA changes these standards, operators must update their own processes or risk:
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More prohibitions at roadside checks
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MOT failures or advisories
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Weak maintenance records
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Higher OCRS scores
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Calls from the DVSA or even a Public Inquiry
Knowing the updates early helps you stay ahead and avoid enforcement action.
Key Changes Across the 2025 Manuals
The latest updates focus on improving safety, tightening defect standards, and giving clearer instructions to inspectors. Operators must make sure their systems reflect these changes.
1. Stricter Brake Performance Requirements
The DVSA has placed more emphasis on brake testing and brake system condition.
What’s important:
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More detailed guidance on imbalance and efficiency failures
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Clearer requirements for roller brake testing
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Stronger expectations for year-round brake performance checks
What you must do:
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Schedule brake tests at regular intervals
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Review reports for trends, not only defects
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Keep all brake records clear and accessible
Brake performance remains one of the top reasons vehicles fail MOTs.
2. Updated Tyre and Wheel Safety Rules
Tyres and wheel fixings now have more detailed defect categories.
Changes include:
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Expanded definitions of unsafe tyre damage
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Clearer rules on age restrictions
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More detail for cracked wheels and loose fixings
What operators should change:
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Improve tyre checks during walk-arounds
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Train drivers to spot sidewall damage
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Strengthen tyre replacement policies
Tyre-related prohibitions remain common in roadside stops.
3. More Focus on Electrical System Safety
Lighting faults are still one of the most frequent MOT failures. The DVSA has updated the manual to reflect modern lighting systems.
Key additions:
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More detail on LED lights
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Clearer criteria for insecure wiring
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Updated requirements for daytime running lights
What you must do:
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Train drivers to check lights effectively
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Make electrical checks a routine part of maintenance
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Repair damaged wiring immediately
Good lighting checks reduce roadside prohibitions.
4. Stronger Load Security Expectations
Load security remains a major safety priority, and the DVSA has strengthened the rules again.
New guidance includes:
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Additional examples of poor and acceptable load restraint
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Clarification for curtain-sided vehicles
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Mixed-load security expectations
What operators must do:
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Update load security training
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Use approved securing equipment
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Carry out periodic internal checks
Load security issues often trigger immediate prohibitions.
5. Steering and Suspension Checks Expanded
Steering and suspension components have clearer definitions of wear and failure points.
Updates include:
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New categories for leaks in air suspension
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Detailed definitions of “excessive wear”
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Improved criteria for joints and linkages
Action required:
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Review maintenance inspection templates
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Replace worn components early
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Train technicians on new definitions
These updates help inspectors judge safety more consistently.
6. Tougher Emissions and Exhaust System Checks
The DVSA continues to focus on air quality and emission compliance.
Updates:
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Clearer smoke test guidance
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New defect categories for exhaust leaks
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Stronger wording on tampering with emissions equipment
Operator responsibilities:
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Investigate any warning lights
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Keep emissions equipment fully functional
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Prevent drivers from ignoring early symptoms
Emission failures can damage your OCRS score quickly.
7. Higher Standards for Record Keeping
The DVSA expects operators to maintain accurate, detailed, and easy-to-access records.
Enhanced expectations cover:
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Recording repeat defects
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Storing brake reports
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Logging repairs
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Tracking inspection patterns
Operators with poor record systems often receive the harshest penalties.
What Operators Should Do Now
To stay compliant with the updated manuals, operators must strengthen their internal processes.
Your immediate tasks:
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Update maintenance inspection sheets
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Review driver walk-around checklists
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Train drivers and technicians on new standards
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Improve brake test planning
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Review your defect reporting process
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Check your record-keeping system is complete and organised
Operators who act early will avoid unnecessary MOT failures and DVSA attention.
How Blue Flag Transport Consulting Helps You Adapt
Blue Flag provides hands-on support to help operators understand and apply these manual updates across their business.
Their support includes:
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Full compliance and maintenance audits
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Updated inspection templates and checklists
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Driver and technician training
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Brake testing strategy reviews
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Record-keeping improvements
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Regular compliance monitoring
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Preparation for DVSA visits
With expert support, operators can implement the new standards quickly and with confidence.
The DVSA’s updates to the HGV and PSV Inspection Manuals affect every operator, whether you run one vehicle or a full fleet. Staying compliant protects your Operator Licence and reduces the risk of costly enforcement action.
With Blue Flag Transport Consulting, you gain the knowledge and systems needed to meet DVSA expectations and keep your fleet safe, legal, and roadworthy.
Contact Blue Flag Transport Consulting Today
Need help adapting to the DVSA manual updates? Contact Blue Flag Transport Consulting for expert guidance, updated templates, and full compliance support tailored to your fleet.
