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December 3, 2021 NHTSA CAMPAIGN NUMBER: 21V940000
The incorrect rear brake pads may not work as intended, increasing the risk of a crash.
NHTSA Campaign Number: 21V940
Manufacturer Zero Motorcycles Inc.
Components SERVICE BRAKES, HYDRAULIC
Potential Number of Units Affected 45
Summary
Zero Motorcycles, Inc. (Zero) is recalling certain 2022 SR, SR/F, and SR/S motorcycles. The incorrect rear brake pads were installed. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 122, “Motorcycle Brake System.”
Remedy
Dealers will inspect and replace the rear brake pads, free of charge. Owner notification letters were mailed January 10, 2021. Owners may contact Zero customer service at 1-888-841-8085. Zero’s number for this recall SV-ZMC-022-018.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Purpose
Zero Motorcycles has determined that certain model year 2022 Zero SR, Zero SR/F and Zero SR/S model manufactured between November 15, 2021 and November 22, 2021 may fail to comply with FMVSS 122. The subject motorcycles were manufactured with rear brake pads that are different from the brake pads that were used to certify compliance with FMVSS 122. Accordingly, Zero Motorcycles cannot confirm compliance. If the motorcycles do not comply with FMVSS 122, the rear brakes may not work as intended and a crash without warning could occur.
In the interest of motor vehicle safety and customer satisfaction, Zero Motorcycles has elected to initiate a voluntary recall (Campaign 21V-940) to remedy this issue. The remedy is to have Zero Motorcycles dealers inspect and replace the rear brake pads on affected motorcycles
It is a violation of Federal law for you to deliver any new motorcycle in your inventory that is affected by this recall until the remedy is completed. You may sell an affected motorcycle, but you may not deliver it prior to the remedy being completed. In addition, Zero Motorcycles urges each dealer to repair any previously owned motorcycles that are in its inventory prior to resale to a consumer.
Applicable Models
The recall population of 45 motorcycles includes model year 2022 Zero SR, Zero SR/F and Zero SR/S motorcycles manufactured between November 15, 2021 and November 22, 2021. The last five digits of the vehicle identification number of affected motorcycles will be 19765 or lower.
Owner Notification
In accordance with Federal regulations administered by NHTSA, Zero Motorcycles will send a letter to registered owners of affected motorcycles, notifying them of this regulatory compliance condition and instructing them to contact their dealer for the associated remedy. Zero will also try to contact these customers via email.
To protect the safety of our riders, it is our mutual responsibility to ensure the recall rework is performed on all affected motorcycles. Therefore, we strongly encourage you reach out to your customers to make sure that they are aware of this program. You are also required by law to perform the recall service on all affected new motorcycles in your inventory prior to delivery to your customers, and we urge you to perform the recall service on any previously owned motorcycles in your inventory.
If you are aware of any unregistered owners of this affected motorcycle population, please advise us of their names, addresses and VINs, so that we may mail them the owner’s letter, as required by Federal law.
If you are not sure that this safety recall has been performed on a particular motorcycle, please contact Zero Motorcycles Customer Service for verification.
Tools Required
Parts Required
- 25-08149 – REAR BRAKE PADS SET SBS-SI-80GG – The correct rear brake pads have a copper backing and are marked with the 35100NT0/35101NT0 manufacturer part numbers and SBS-SI80GG surface treatment number.
CAUTION: The incorrect rear brake pads have a silver backing and are marked with the 352024NT0/ 352025NT0 manufacturer part numbers and SBS-S-60HH surface treatment number. See image below of the incorrect brake pads. Be sure to mark them or destroy them to avoid future use.
Procedure
The procedure consists of three steps: removing the old and incorrect brake pads, replacing them with the new brake pads and then performing the brake pad bedding procedure. Please note that the procedure pictures below show the correct brake pads with the copper backing being replaced as available in the current service manual.
1. Remove rear brake caliper retaining pin.
2. Remove rear brake caliper pin bolt. Tool: T25.
3. The eyelet end of the brake pads need to drop in order to release it from the caliper.
4. Remove both rear caliper brake pads.
5. Installation of the new brake pads is the revers of the above removal procedure. When installing the rear brake caliper pin bolt, it should be torqued to 6 ft-lb (8 Nm).
6. After installing the new brake pads, perform the brake pad bedding procedure as follows.
CAUTION: With new brake pads, the first few braking applications will result in very little braking power. Gently use the brakes a few times at low speeds (<25 mph) to develop proper braking friction.
From 50 mph, apply the brakes firmly, but do not lock up the tires or engage ABS. Slow down to 10 mph. Do not come to a complete stop as this can cause the pad material to become imprinted on the rotor causing vibration.
Gradually accelerate back up to 50 mph. This will prevent the brake system from overheating.
Repeat previous steps 15-20 times.
Chronology :
For the 2015 Model Year, after FMVSS 122 brake certification, Zero Motorcycles introduced the rear brake pads (PN 25-08030) on its SDS motorcycle platform.
For the 2020 Model Year, after FMVSS 122 brake certification, Zero Motorcycles introduced the rear brake pads (PN 25-08149) on its FST motorcycle platform (SR/F models), using the same caliper and rotor material as on the SDS platform. The FST platform has a max GVWR of 1000 lbs vs. the SDS platform max GVWR of 906 lbs.
On November 15, 2021, Zero started production of the 2020 Model Year FST platform (SR/F/S models), mistakenly using the SDS platform rear brake pads. This production build included the Zero Quality Launch Plan motorcycles, which were tested to more than 500 miles each, without Zero Motorcycle’s test riders noticing any difference in brake performance.
On November 22, 2021, Zero Motorcycles Final Quality Inspection (“FQC”) team discovered that they were receiving motorcycles with the incorrect rear brake pads at the end of the production line. As a result of these reports, Zero Motorcycles Production and Quality Teams investigated the rear brake pads on the line and installed in recently completed motorcycles. This team confirmed that the incorrect rear brake pads were being utilized since November 15, 2021. The production line inventory was corrected and additional inspections were implemented on November 22, 2021.
On November 29, 2021, the Product Integrity Team at Zero met to review the use of the incorrect rear brake pads. Based on this meeting, this team confirmed that the rear brake pads installed were different from those used for compliance certification for the model year 2022 Zero SR/F/S motorcycles and recommended the company take steps to voluntarily pursue a regulatory recall.
Zero Motorcycles is not aware of any accidents or injuries caused by this defect.
3 Affected Products
Vehicles
MAKE | MODEL | YEAR |
ZERO | SR | 2022 |
ZERO | SR/F | 2022 |
ZERO | SR/S | 2022 |
8 Associated Documents
Recall Acknowledgement
RCAK-21V940-9976.pdf 645.097KB
Noncompliance Notice 573 Report
RCLRPT-21V940-2611.PDF 216.252KB
Recall 573 Report-Amendment 1
RCLRPT-21V940-5360.PDF 216.253KB
Manufacturer Notices(to Dealers,etc) – Date: December 13, 2021 Model Year 2022 Zero SR/F/S Rear Brake Pads Recall
RCMN-21V940-5202.pdf 651.666KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V940-0085.pdf 110.669KB
Recall Quarterly Report #1, 2022-1
RCLQRT-21V940-9489.PDF 211.149KB
Recall Quarterly Report #2, 2022-2
RCLQRT-21V940-5640.PDF 211.248KB
Recall Quarterly Report #3, 2022-3
RCLQRT-21V940-6359.PDF 211.329KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V940&docType=RCL
- Made using high pressure die cast alluminium platforms with bonded brake linings
- All shoes are radius ground and edge trimmed
- Features lead in and lead out chamfers at lining ends
- Original equipment style brake shoe springs included
- Fits: Harley Davidson FLHX Street Glide 2008-2013, FLHX Street Glide 2014-2015, FLHXS Street Glide Special 2015
- Complete Double-H Sintered Brake Pad Change Kit includes 2 EBC FA409HH Front Brake Pads and 1 EBC FA409HH Rear Brake Pad
- Double-H Sintered Brake Pads deliver high performance and are well known as the EBC flagship sintered high-performance brake pad
- ECE R 90 brake safety approved and TUV tested, these ultra high friction HH rated brake pads remain a market leader above the rest as nothing else beats the performance of the Double-H Sintered Brake Pad
- Manufactured in the US in the state-of-the-art sintering plant in Ohio, Double-H Sintered Brake Pads perform well in all weather conditions be it dry or wet and have a high longevity lasting for many miles
- 【Fitment】Fit for Harley Davidson Motorcycle ▶ Electra Glide FLHT 2008-2020 ▶ Night Rod VRSCD 2006-2011 ▶ Road Glide FLTR 2008-2020 ▶ Road King FLHR 2008-2020
- 【Fitment】 ▶ Street Glide FLHX 2008-2020 ▶ Street Rod VRSCR 2006-2007 ▶ Tri Glide FLHTCUTG 2008-2013 2019-2020 ▶ Ultra Limited FLHTK 2014-2020 ▶ V-Rod VRSC 2005-2017
- 【Material】1. With copper plating base is good for dissipation 2.Sintered by copper and tin formula compound is designed to any poor condictions.
- 【OEM#】41854-08 42850-06 42897-06 42897-08 FA409. 【Repalcement OEM#】42850-06A 42897-06A
- 【Package】Brake Pads Set x 3. Not included instruction manual. Easy to install
- Made using high pressure die cast alluminium platforms with bonded brake linings
- All shoes are radius ground and edge trimmed
- Features lead in and lead out chamfers at lining ends
- Original equipment style brake shoe springs included
- Made using high pressure die cast alluminium platforms with bonded brake linings
- All shoes are radius ground and edge trimmed
- Features lead in and lead out chamfers at lining ends
- Original equipment style brake shoe springs included
- 【Fit Models】HARLEY DAVIDSON TOURING SERIES, FLHX Street Glide:2008-2014 FLHR Road King (Spoke Wheel Type):2008-2016 FLHRC Road King Classic | FLHTCU Ultra Classic Electra Glide :2008-2018 FLHRXS Road King Special | FLHTK Electra Glide Ultra Ltd Anniv | FLHTK Electra Glide Ultra Ltd Shrine Edition | FLHX Street Glide Anniv | FLHXS Street Glide Special Anniv:2018 FLTR Road Glide: 2008-2009 FLHT Electra Glide Standard: 2008-2010 FLHTC Electra Glide Classic: 2008-2012
- 【Fit Models】HARLEY DAVIDSON TOURING SERIES, FLTRX Road Glide Custom: 2010-2012 FLHTK Electra Glide Ultra Ltd:2010-2013 FLHTCUL Electra Glide Ultra Classic Low: 2015-2016 FLHR Road King (Cast Wheel Type) | FLHXS Street Glide Special | FLTRX Road Glide | FLTRXS Road Glide Special | FLHTK Ultra Ltd | FLHTKL Ultra Ltd Low: 2015-2018 FLTRU Road Glide Ultra: 2011-2012 2016-2017
- 【Fit Models】HARLEY DAVIDSON TOURING SERIES, FLTRX Road Glide Custom: 2010-2012 FLHTK Electra Glide Ultra Ltd:2010-2013 FLHTCUL Electra Glide Ultra Classic Low: 2015-2016 FLHR Road King (Cast Wheel Type) | FLHXS Street Glide Special | FLTRX Road Glide | FLTRXS Road Glide Special | FLHTK Ultra Ltd | FLHTKL Ultra Ltd Low: 2015-2018 FLTRU Road Glide Ultra: 2011-2012 2016-2017
- 【Package Include】Full set included 2 sets front and 1set rear brake pads
- 【High quality】Sintered compound for hard stopping power with less fade and longer pad life
- Made using high pressure die cast alluminium platforms with bonded brake linings
- All shoes are radius ground and edge trimmed
- Features lead in and lead out chamfers at lining ends
- Original equipment style brake shoe springs included
- All shoes are radius ground and edge trimmed
- Package Dimensions: 15.748 H x 1.016 L x 12.192 W (centimetres)
- Package Weight: 0.227 kilograms
- Country of Origin : Wales
- Made using high pressure die cast alluminium platforms with bonded brake linings
- Made using high pressure die cast alluminium platforms with bonded brake linings
- All shoes are radius ground and edge trimmed
- Features lead in and lead out chamfers at lining ends
- Original equipment style brake shoe springs included
- Made using high pressure die cast alluminium platforms with bonded brake linings
- All shoes are radius ground and edge trimmed
- Features lead in and lead out chamfers at lining ends
- Original equipment style brake shoe springs included
Last update on 2024-06-11 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.
SEOCONTENT-START
Zero Motorcycles Inc., 380 El Pueblo Rd, Scotts Valley, California, USA 95066 (831) 438-3500 – www.zeromotorcycles.com [VIA REGISTERED MAIL AND EMAIL] IMPORTANT SAFETY RECALL This notice applies to your vehicle with VIN#[VIN NUMBER] Recall SV-ZMC-022-418 / NHTSA Recall #21V-940 [Name] [Address] [City, State Postal Code] January 10, 2021 Dear Zero Motorcycle Owner, This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Zero Motorcycles has decided that certain model year 2022 Zero SR, Zero SR/F and Zero SR/S model motorcycles built between November 15, 2021 and November 22, 2021 fail to comply with Federal Motor Vehicle Safety Standard No. 122, “Motorcycles Brake System.” The subject motorcycles were manufactured with rear brake pads that are different from the brake pads that were used to certify compliance with FMVSS 122. The rear brakes may not work as intended and a crash without warning could occur. Our records indicate that you purchased one of the motorcycles listed above. We strongly urge you to contact your Zero Motorcycles dealer to make arrangements to have the appropriate service performed as soon as possible. Should you choose to ride your motorcycle prior to this service, we urge you to be aware of this condition. The remedy of this defect is for a Zero Motorcycles authorized dealer to inspect and replace the rear brake pads. Should you choose to ride your suspect motorcycle prior to having your dealer perform this rework, you should be aware of this condition and brake cautiously including using the front brakes. Please contact your Zero Motorcycles dealer immediately and arrange an appointment to have your motorcycle repaired. If you are unsure of the location of your nearest authorized dealer, please use the dealer locator located on our website at https://www.zeromotorcycles.com/dealer-locator. The actual dealer labor time to perform this service will be approximately 20 minutes; however, due to scheduling, the dealer may require your motorcycle for a longer period. The parts and labor will be free of charge to you. Replacement parts are now available for order by your dealer. Zero Motorcycles Inc., 380 El Pueblo Rd, Scotts Valley, California, USA 95066 (831) 438-3500 – www.zeromotorcycles.com If you no longer own this motorcycle, please contact us at 1-888-841-8085 so we may update our records and notify the new owner. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. If your dealer or Zero Motorcycles fails or is unable to remedy your motorcycle without charge within a reasonable time, you may wish to inform the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call the toll-free hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or contact NHTSA at http://www.safecar.gov. We value safety above all else and strive for the highest standards in ride quality and experience, and we deeply regret this inconvenience. Zero Motorcycles would not be issuing this action if it were not in the interest of your personal safety, satisfaction and enjoyment of your Zero motorcycle. Thank you for your understanding, and we look forward to a swift and smooth remediation of this issue. Regards, Aaron S. Cheatham Chief of Staff Zero Motorcycles, Inc.
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Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: December 13, 2021 Source: Zero Motorcycles Customer Service Department If you have any questions, please contact the Customer Service Team. In the Americas: 888-RUN-ZERO (888-786-9376) Ext 2 In the EMEA region: +31 (0) 72 5112014 1 SV-ZMC-022-018 Rev 1 Model Year 2022 Zero SR/F/S Rear Brake Pads Recall NHTSA Campaign Number: 21V-940 Purpose Zero Motorcycles has determined that certain model year 2022 Zero SR, Zero SR/F and Zero SR/S model manufactured between November 15, 2021 and November 22, 2021 may fail to comply with FMVSS 122. The subject motorcycles were manufactured with rear brake pads that are different from the brake pads that were used to certify compliance with FMVSS 122. Accordingly, Zero Motorcycles cannot confirm compliance. If the motorcycles do not comply with FMVSS 122, the rear brakes may not work as intended and a crash without warning could occur. In the interest of motor vehicle safety and customer satisfaction, Zero Motorcycles has elected to initiate a voluntary recall (Campaign 21V-940) to remedy this issue. The remedy is to have Zero Motorcycles dealers inspect and replace the rear brake pads on affected motorcycles It is a violation of Federal law for you to deliver any new motorcycle in your inventory that is affected by this recall until the remedy is completed. You may sell an affected motorcycle, but you may not deliver it prior to the remedy being completed. In addition, Zero Motorcycles urges each dealer to repair any previously owned motorcycles that are in its inventory prior to resale to a consumer. Applicable Models The recall population of 45 motorcycles includes model year 2022 Zero SR, Zero SR/F and Zero SR/S motorcycles manufactured between November 15, 2021 and November 22, 2021. The last five digits of the vehicle identification number of affected motorcycles will be 19765 or lower. Owner Notification In accordance with Federal regulations administered by NHTSA, Zero Motorcycles will send a letter to registered owners of affected motorcycles, notifying them of this regulatory compliance condition and instructing them to contact their dealer for the associated remedy. Zero will also try to contact these customers via email. To protect the safety of our riders, it is our mutual responsibility to ensure the recall rework is performed on all affected motorcycles. Therefore, we strongly encourage you reach out to your customers to make sure that they are aware of this program. You are also required by law to perform the recall service on all affected new motorcycles in your inventory prior to delivery to your customers, and we urge you to perform the recall service on any previously owned motorcycles in your inventory. If you are aware of any unregistered owners of this affected motorcycle population, please advise us of their names, addresses and VINs, so that we may mail them the owner’s letter, as required by Federal law. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: December 13, 2021 Source: Zero Motorcycles Customer Service Department If you have any questions, please contact the Customer Service Team. In the Americas: 888-RUN-ZERO (888-786-9376) Ext 2 In the EMEA region: +31 (0) 72 5112014 2 SV-ZMC-022-018 Rev 1 If you are not sure that this safety recall has been performed on a particular motorcycle, please contact Zero Motorcycles Customer Service for verification. Tools Required • T25 Torx T-Handle or T25 Torx Bit Socket and Ratchet Parts Required • 25-08149 – REAR BRAKE PADS SET SBS-SI-80GG – The correct rear brake pads have a copper backing and are marked with the 35100NT0/35101NT0 manufacturer part numbers and SBS-SI-80GG surface treatment number. CAUTION: The incorrect rear brake pads have a silver backing and are marked with the 352024NT0/ 352025NT0 manufacturer part numbers and SBS-S-60HH surface treatment number. See image below of the incorrect brake pads. Be sure to mark them or destroy them to avoid future use. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: December 13, 2021 Source: Zero Motorcycles Customer Service Department If you have any questions, please contact the Customer Service Team. In the Americas: 888-RUN-ZERO (888-786-9376) Ext 2 In the EMEA region: +31 (0) 72 5112014 3 SV-ZMC-022-018 Rev 1 Procedure The procedure consists of three steps: removing the old and incorrect brake pads, replacing them with the new brake pads and then performing the brake pad bedding procedure. Please note that the procedure pictures below show the correct brake pads with the copper backing being replaced as available in the current service manual. 1. Remove rear brake caliper retaining pin. 2. Remove rear brake caliper pin bolt. Tool: T25. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: December 13, 2021 Source: Zero Motorcycles Customer Service Department If you have any questions, please contact the Customer Service Team. In the Americas: 888-RUN-ZERO (888-786-9376) Ext 2 In the EMEA region: +31 (0) 72 5112014 4 SV-ZMC-022-018 Rev 1 3. The eyelet end of the brake pads need to drop in order to release it from the caliper. 4. Remove both rear caliper brake pads. 5. Installation of the new brake pads is the revers of the above removal procedure. When installing the rear brake caliper pin bolt, it should be torqued to 6 ft-lb (8 Nm). 6. After installing the new brake pads, perform the brake pad bedding procedure as follows. CAUTION: With new brake pads, the first few braking applications will result in very little braking power. Gently use the brakes a few times at low speeds (<25 mph) to develop proper braking friction. From 50 mph, apply the brakes firmly, but do not lock up the tires or engage ABS. Slow down to 10 mph. Do not come to a complete stop as this can cause the pad material to become imprinted on the rotor causing vibration. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: December 13, 2021 Source: Zero Motorcycles Customer Service Department If you have any questions, please contact the Customer Service Team. In the Americas: 888-RUN-ZERO (888-786-9376) Ext 2 In the EMEA region: +31 (0) 72 5112014 5 SV-ZMC-022-018 Rev 1 Gradually accelerate back up to 50 mph. This will prevent the brake system from overheating. Repeat previous steps 15-20 times. Timing and Reimbursement To receive reimbursement for the work performed and any parts used under this service campaign, the dealer must submit a Warranty Claim for the replacement costs incurred that includes the following information: • Fault Summary: MY22 Zero SR/F/S Rear Brake Pads Recall • Fault Area: 25-Brake • Fault Code: 90-Service Bulletin Recall • Service Bulletin / Recall: MY22 Zero SR/F/S Rear Brake Pad Recall • Warranty Claim Type: Service Bulletin/Recall See example below for full details. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: December 13, 2021 Source: Zero Motorcycles Customer Service Department If you have any questions, please contact the Customer Service Team. In the Americas: 888-RUN-ZERO (888-786-9376) Ext 2 In the EMEA region: +31 (0) 72 5112014 6 SV-ZMC-022-018 Rev 1 Zero Motorcycles believes that the time that should be allotted to this work is 30 minutes (0.5 hours). We do not reimburse any costs related to towing or loaner/temporary replacement motorcycles/vehicles. Technical Cases for affected motorcycles have been created by Zero Motorcycles. To find the matching case number in the Partner Community select the “Support” tab: Click on the “Start New Case” button and enter the last 5 digits of the frame number in the “Enter Vehicle Identification Number” field: Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: December 13, 2021 Source: Zero Motorcycles Customer Service Department If you have any questions, please contact the Customer Service Team. In the Americas: 888-RUN-ZERO (888-786-9376) Ext 2 In the EMEA region: +31 (0) 72 5112014 7 SV-ZMC-022-018 Rev 1 You will find the matching case it the Open Service Notification list.
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-940 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Zero Motorcycles Inc. Submission Date : DEC 09, 2021 NHTSA Recall No. : 21V-940 Manufacturer Recall No. : SV-ZMC-022-018 Manufacturer Information : Manufacturer Name : Zero Motorcycles Inc. Address : 380 El Pueblo Road Scotts Valley CA 95066 Company phone : 831-438-3500 Population : Number of potentially involved : 45 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2022 Zero Motorcycles Zero SR, Zero SR/F and Zero SR/S Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : Model year 2022 Zero SR, Zero SR/F and Zero SR/S motorcycles manufactured between November 15, 2021 and November 22, 2021. The last five digits of the vehicle identification number of affected motorcycles will be 19765 or lower. Production Dates : NOV 15, 2021 – NOV 22, 2021 VIN Range 1 : Begin : 538ZFCZ77NCP19623 End : 538ZFDZ76NCK19765 ✔ Not sequential Description of Noncompliance : Description of the Noncompliance : The subject motorcycles were manufactured with rear brake pads that are different from the brake pads that were used to certify compliance with FMVSS 122. Accordingly, Zero Motorcycles cannot confirm compliance. FMVSS 1 : 122 – Motorcycle brake systems FMVSS 2 : NR Description of the Safety Risk : If the motorcycles do not comply with FMVSS 122, the rear brakes may not work as intended and a crash without warning could occur. Description of the Cause : Zero Motorcycles operations personnel placed the wrong parts on the manufacturing line for the subject motorcycles. These motorcycles were correctly assembled with the incorrect rear brake pads, which do not match current regulatory filings. Identification of Any Warning that can Occur : NR Involved Components : Part 573 Safety Recall Report 21V-940 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : BRAKE PADS SET SBS-S-60HH REAR SDS Component Description : BRAKE PADS SET SBS-S-60HH REAR SDS Component Part Number : 25-08030 Component Name 2 : REAR BRAKE PADS SET SBS-SI-80GG Component Description : REAR BRAKE PADS SET SBS-SI-80GG Component Part Number : 25-08149 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : For the 2015 Model Year, after FMVSS 122 brake certification, Zero Motorcycles introduced the rear brake pads (PN 25-08030) on its SDS motorcycle platform. For the 2020 Model Year, after FMVSS 122 brake certification, Zero Motorcycles introduced the rear brake pads (PN 25-08149) on its FST motorcycle platform (SR/F models), using the same caliper and rotor material as on the SDS platform. The FST platform has a max GVWR of 1000 lbs vs. the SDS platform max GVWR of 906 lbs. On November 15, 2021, Zero started production of the 2020 Model Year FST platform (SR/F/S models), mistakenly using the SDS platform rear brake pads. This production build included the Zero Quality Launch Plan motorcycles, which were tested to more than 500 miles each, without Zero Motorcycle’s test riders noticing any difference in brake performance. On November 22, 2021, Zero Motorcycles Final Quality Inspection (“FQC”) team discovered that they were receiving motorcycles with the incorrect rear brake pads at the end of the production line. As a result of these reports, Zero Motorcycles Production and Quality Teams investigated the rear brake pads on the line and installed in recently completed motorcycles. This team confirmed that the incorrect rear brake pads were being utilized since November 15, 2021. The production line inventory was corrected and additional inspections were implemented on November 22, 2021. Part 573 Safety Recall Report 21V-940 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 On November 29, 2021, the Product Integrity Team at Zero met to review the use of the incorrect rear brake pads. Based on this meeting, this team confirmed that the rear brake pads installed were different from those used for compliance certification for the model year 2022 Zero SR/F/S motorcycles and recommended the company take steps to voluntarily pursue a regulatory recall. Zero Motorcycles is not aware of any accidents or injuries caused by this defect. Description of Remedy : Description of Remedy Program : Zero Motorcycles dealers will inspect and replace the rear brake pads on affected motorcycles. Dealers will then submit a warranty claim for the parts and labor related to the replacement. The labor time for replacement is 0.5 hours. Zero Motorcycles has not developed a separate reimbursement plan for this recall because all of the subject motorcycles are under warranty, and no owner should have paid for this repair out of pocket. How Remedy Component Differs from Recalled Component : The incorrect rear brake pads (p/n 25-08030 – BRAKE PADS SET SBSS- 60HH REAR SDS) have silver backing and are marked with the 352024NT0/352025NT0 manufacturer part numbers and SBS-S-60HH surface treatment number. The correct rear brake pads (p/n 25-08149 – REAR BRAKE PADS SET SBS-SI-80GG) have a copper backing and are marked with the 35100NT0/35101NT0 manufacturer part numbers and SBS-SI-80GG surface treatment number. Identify How/When Recall Condition was Corrected in Production : Zero Motorcycles production and logistics teams removed the recalled rear brake pads from the production line on November 22, 2021 and they were immediately replaced with the correct rear brake pads. Additional inspection requirements were confirmed with the Final Quality Inspection team at that time. Recall Schedule : Description of Recall Schedule : Zero Motorcycles expects to notify its dealer network no later than the week of December 13, 2021 and motorcycle owners no later than the week of December 20, 2021. Planned Dealer Notification Date : DEC 13, 2021 – DEC 31, 2021 Planned Owner Notification Date : DEC 20, 2021 – JAN 07, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-940 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Zero Motorcycles Inc. Submission Date : DEC 03, 2021 NHTSA Recall No. : 21V-940 Manufacturer Recall No. : SV-ZMC-022-018 Manufacturer Information : Manufacturer Name : Zero Motorcycles Inc. Address : 380 El Pueblo Road Scotts Valley CA 95066 Company phone : 831-438-3500 Population : Number of potentially involved : 45 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2022 Zero Motorcycles Zero SR, Zero SR/F and Zero SR/S Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : Model year 2022 Zero SR, Zero SR/F and Zero SR/S motorcycles manufactured between November 15, 2021 and November 22, 2021. The last five digits of the vehicle identification number of affected motorcycles will be 19765 or lower. Production Dates : NOV 15, 2021 – NOV 22, 2021 VIN Range 1 : Begin : 538ZFCZ77NCP19623 End : 538ZFDZ76NCK19765 ✔ Not sequential Description of Noncompliance : Description of the Noncompliance : The subject motorcycles were manufactured with rear brake pads that are different from the brake pads that were used to certify compliance with FMVSS 122. Accordingly, Zero Motorcycles cannot confirm compliance. FMVSS 1 : 122 – Motorcycle brake systems FMVSS 2 : NR Description of the Safety Risk : If the motorcycles do not comply with FMVSS 122, the rear brakes may not work as intended and a crash without warning could occur. Description of the Cause : Zero Motorcycles operations personnel placed the wrong parts on the manufacturing line for the subject motorcycles. These motorcycles were correctly assembled with the incorrect rear brake pads, which do not match current regulatory filings. Identification of Any Warning that can Occur : NR Involved Components : Part 573 Safety Recall Report 21V-940 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : BRAKE PADS SET SBS-S-60HH REAR SDS Component Description : BRAKE PADS SET SBS-S-60HH REAR SDS Component Part Number : 25-08030 Component Name 2 : REAR BRAKE PADS SET SBS-SI-80GG Component Description : REAR BRAKE PADS SET SBS-SI-80GG Component Part Number : 25-08149 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : For the 2015 Model Year, after FMVSS 122 brake certification, Zero Motorcycles introduced the rear brake pads (PN 25-08030) on its SDS motorcycle platform. For the 2020 Model Year, after FMVSS 122 brake certification, Zero Motorcycles introduced the rear brake pads (PN 25-08149) on its FST motorcycle platform (SR/F models), using the same caliper and rotor material as on the SDS platform. The FST platform has a max GVWR of 1000 lbs vs. the SDS platform max GVWR of 906 lbs. On November 15, 2021, Zero started production of the 2020 Model Year FST platform (SR/F/S models), mistakenly using the SDS platform rear brake pads. This production build included the Zero Quality Launch Plan motorcycles, which were tested to more than 500 miles each, without Zero Motorcycle’s test riders noticing any difference in brake performance. On November 22, 2021, Zero Motorcycles Final Quality Inspection (“FQC”) team discovered that they were receiving motorcycles with the incorrect rear brake pads at the end of the production line. As a result of these reports, Zero Motorcycles Production and Quality Teams investigated the rear brake pads on the line and installed in recently completed motorcycles. This team confirmed that the incorrect rear brake pads were being utilized since November 15, 2021. The production line inventory was corrected and additional inspections were implemented on November 22, 2021. Part 573 Safety Recall Report 21V-940 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 On November 29, 2021, the Product Integrity Team at Zero met to review the use of the incorrect rear brake pads. Based on this meeting, this team confirmed that the rear brake pads installed were different from those used for compliance certification for the model year 2022 Zero SR/F/S motorcycles and recommended the company take steps to voluntarily pursue a regulatory recall. Zero Motorcycles is not aware of any accidents or injuries caused by this defect. Description of Remedy : Description of Remedy Program : Zero Motorcycles dealers will inspect and replace the rear brake pads on affected motorcycles. Dealers will then submit a warranty claim for the parts and labor related to the replacement. The labor time for replacement is 0.33 hours. Zero Motorcycles has not developed a separate reimbursement plan for this recall because all of the subject motorcycles are under warranty, and no owner should have paid for this repair out of pocket. How Remedy Component Differs from Recalled Component : The incorrect rear brake pads (p/n 25-08030 – BRAKE PADS SET SBSS- 60HH REAR SDS) have silver backing and are marked with the 352024NT0/352024NT0 manufacturer part numbers and SBS-S-60HH surface treatment number. The correct rear brake pads (p/n 25-08149 – REAR BRAKE PADS SET SBS-SI-80GG) have a copper backing and are marked with the 35100NT0/35101NT0 manufacturer part numbers and SBS-SI-80GG surface treatment number. Identify How/When Recall Condition was Corrected in Production : Zero Motorcycles production and logistics teams removed the recalled rear brake pads from the production line on November 22, 2021 and they were immediately replaced with the correct rear brake pads. Additional inspection requirements were confirmed with the Final Quality Inspection team at that time. Recall Schedule : Description of Recall Schedule : Zero Motorcycles expects to notify its dealer network no later than the week of December 13, 2021 and motorcycle owners no later than the week of December 20, 2021. Planned Dealer Notification Date : DEC 13, 2021 – DEC 31, 2021 Planned Owner Notification Date : DEC 20, 2021 – JAN 07, 2022 * NR – Not Reported
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