SV-RCL-022-004 – Front Brake Caliper Bolts – 2022 Zero SR & SR/F Motorcycles

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Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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-RCL-022-004 Rev 1 Model Year 2022 Zero SR and SR/F Front Brake Caliper Bolts Recall NHTSA Campaign Number: 22V-403 Purpose Zero Motorcycles has determined that certain model year 2022 Zero SR and Zero SR/F models manufactured between April 22, 2022 and April 27, 2022 may have been manufactured with incorrect front brake caliper bolts that have a different thread pitch. The incorrect thread pitch could cause damage to the mounting threads on the fork, which could reduce the clamping load, which in turn could cause the caliper to come loose. If the caliper were to come loose, braking force could be reduced, which could cause a crash. In the interest of motor vehicle safety and customer satisfaction, Zero Motorcycles has elected to initiate a voluntary recall (Campaign 22V-403) to remedy this issue. The remedy is to have Zero Motorcycles dealers inspect and, if necessary, replace the front brake caliper bolt/s and fork/s 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 23 motorcycles includes model year 2022 Zero SR and Zero SR/F motorcycles manufactured between April 22, 2022 and April 27, 2022. The last five digits of the vehicle identification number of affected motorcycles will be between 21423 and 21486. 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 recall 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. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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-RCL-022-004 Rev 1 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 – For Caliper Bolt Inspection • T50 Torx Bit, or 13mm socket, Ratcheting Wrench, and Torque Wrench Parts Required • Zero Motorcycles Part Number 90-08134 – HEX FLANG BOLT STAR DRIVE PER ZM 88-08813 M10X55X1.25 THREAD 10.9 ZM-F-01 ZM-L-02 – These bolts for the front calipers are 55 mm in length with a thread pitch of 1.25, with thread patch locking compound pre-applied. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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-RCL-022-004 Rev 1 CAUTION: The incorrect brake caliper bolts are similar in appearance with measurements of: M10x60x1.50. These bolts are 5mm longer than the correct bolt with a coarser thread pitch. This difference in size and thread pitch can cause a failure in the clamping load holding the caliper to the affected fork, resulting in loss of braking force. See image below of the incorrect brake caliper bolts. Be sure to mark them and dispose of them properly. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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-RCL-022-004 Rev 1 Procedure The recall consists of two steps outlined below: removing the front brake caliper bolts one at a time for inspection and length measurement. A. If the bolts are 55mm in length and come out smoothly, reinstall and torque to appropriate value (30 ft-lbs). B. If the bolts are NOT 55mm in length, or significant force is required to remove bolt from the fork it must be assumed that the incorrect bolt has been used. – As stated in A, if the correct bolts were observed to be installed, no further action Is required after reassembly. – However, if the bolts are longer than anticipated or do not come out easily, as described in B, the affected fork bolt/s and leg/s must be replaced. The procedure for fork leg/s replacement can be found in the service manual for these motorcycles. – Record the length of each bolt on the table below. Any bolt length other than 55mm necessitates bolt and associated fork/s replacement. BOLT POSITION ACTUAL BOLT LENGTH (MM) SPECIFIED BOLT LENGTH (MM) RIDER LEFT, UPPER 55 RIDER LEFT, LOWER 55 RIDER RIGHT, UPPER 55 RIDER RIGHT, LOWER 55 Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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-RCL-022-004 Rev 1 1. Remove front brake caliper bolts, one at a time to measure them. [Tool: T50, Torque: 30 ft-lbs] Note: For left upper caliper bolt, take note of position of wheel speed sensor wiring clip position, as shown in Fig. 1. Figure 1 2. Measure and record brake caliper bolt length. Each bolt must be 55mm in length, or bolt and fork must be replaced. Figure 2 Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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-RCL-022-004 Rev 1 3. If the bolt is the correct length, 55mm, no further corrective action is required. [Reinstall bolt and torque to 30 ft-lbs] Figure 3 4. Remove next bolt in caliper to measure length. Figure 4 Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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-RCL-022-004 Rev 1 5. Measure and record brake caliper bolt length. Each bolt must be 55mm in length, or bolt and fork must be replaced. Figure 5 6. If bolt is the correct length, 55mm, no corrective action is needed. [Reinstall bolt and torque to 30 ft-lbs] 7. Ensure that all 4 brake caliper bolts have been measured and recorded. If ANY bolt measures longer than 55mm, or is extremely difficult to remove, the associated fork and brake caliper bolts must be replaced. [Replacement instructions for the front forks can be found in the service manual.] Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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 8 SV-RCL-022-004 Rev 1 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: 2022 Zero SR and SR/F Front Brake Caliper Bolt Recall • Fault Area: 25-Brake • Fault Code: 90-Service Bulletin Recall • Service Bulletin / Recall: 22MY Zero SRF-SR Front Brake Caliper Bolt Recall • Warranty Claim Type: Service Bulletin/Recall See example below for full details. Zero Motorcycles believes that the time that should be allotted to this work is 0.25 hours for inspection and 0.30 hours for replacement (per fork). We do not reimburse any costs related to towing or loaner/temporary Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: June 20, 2022 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 9 SV-RCL-022-004 Rev 1 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: You will find the matching case it the Open Service Notification list.

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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#538XXXXXXXXXXXXXX Recall SV-RCL-022-004 / NHTSA Recall #22V403 June 27, 2022 Name Address City, State Postal 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 and Zero SR/F model motorcycles built between April 22, 2022 and April 27, 2022 fail to comply with Federal Motor Vehicle Safety Standard No. 122, “Motorcycles Brake System.” The subject motorcycles may have been manufactured with incorrect front brake caliper bolts that have a different thread pitch. The incorrect thread pitch could cause damage to the mounting threads on the fork, which could reduce the clamping load, which in turn could cause the caliper to come loose. If the caliper were to come loose, braking force could be reduced, which could cause a crash. 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 the front brake caliper bolts, and as necessary, replace the bolt/s and fork/s. 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. 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 inspection will be approximately 20 minutes; however, due to scheduling, the dealer may require your motorcycle for a longer period if the bolt/s and fork/s need to be replaced. 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, Chris M. Langlois Director of Technical and Commercial Services Zero Motorcycles, Inc.

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-403 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Zero Motorcycles Inc. Submission Date : JUN 08, 2022 NHTSA Recall No. : 22V-403 Manufacturer Recall No. : SV-RCL-022-004 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 : 23 Estimated percentage with defect : 10 % Vehicle Information : Vehicle 1 : 2022-2022 Zero Motorcycles SR/F Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : Model year 2022 Zero SR/F and Zero SR motorcycles manufactured between April 22, 2022 and April 27, 2022. The last five digits of the vehicle identification number of affected motorcycles are between 21423 and 21486. Production Dates : APR 22, 2022 – APR 27, 2022 VIN Range 1 : Begin : 538ZFDZ7XNCK21423 End : 538ZFCZ70NCP21486 Not sequential Vehicle 2 : 2022-2022 Zero Motorcycles SR Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : Model year 2022 Zero SR/F and Zero SR motorcycles manufactured between April 22, 2022 and April 27, 2022. The last five digits of the vehicle identification number of affected motorcycles are between 21423 and 21486. Production Dates : APR 22, 2022 – APR 27, 2022 VIN Range 1 : Begin : 538ZFDZ7XNCK21423 End : 538ZFCZ70NCP21486 Not sequential Description of Defect : Description of the Defect : The subject motorcycles may have been manufactured with front brake caliper bolts that have a different thread pitch that can cause damage to the mounting threads on the fork. FMVSS 1 : NR FMVSS 2 : NR Part 573 Safety Recall Report 22V-403 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of the Safety Risk : The incorrect thread pitch could cause damage to the mounting threads on the fork, which could reduce the clamping load, which in turn could cause the caliper to come loose. If the caliper were to come loose, braking force could be reduced, which could cause a crash. Description of the Cause : Zero Motorcycles operations personnel placed the wrong parts on the manufacturing line along with correct parts for the subject motorcycles. These motorcycles were correctly assembled but may have used incorrect bolts. Identification of Any Warning that can Occur : If a caliper were to come loose, rattling or knocking noises could be heard during braking events leading up to reduced braking force. Involved Components : Component Name 1 : HEX FLANGE BOLT STAR DRIVE PER ZM 88-08813 M10X60 Component Description : HEX FLANGE BOLT STAR DRIVE PER ZM 88-08813 M10X60 8.8 ZM-F-01 ZML- 02 Component Part Number : 90-08142 Component Name 2 : HEX FLANGE BOLT STAR DRIVE PER ZM 88-08813 M10X55X Component Description : HEX FLANGE BOLT STAR DRIVE PER ZM 88-08813 M10X55X1.25 THREAD 10.9 ZM-F-01 ZM-L-02 Component Part Number : 90-08134 Supplier Identification : Component Manufacturer Name : BOSSARD NORTH AMERICA INC Address : 47849 Fremont Blvd Fremont California 94538 Country : United States Chronology : 5/11/22 Production engineering alerted Quality engineering to an issue on the production line (station VB06 FST) where the front brake caliper bolt would not install properly on VIN#21652. It was found that the incorrect bolt was being used; the incorrect bolt is similar in appearance but has coarse threads and is 5mm longer. When installed, the incorrect bolt will damage the mating threads inside the fork. VIN#21652 was taken Part 573 Safety Recall Report 22V-403 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 offline and the front forks were replaced. Correct bolt P/N 90-08134 M10x55x1.25. Incorrect bolt P/N 90-08142 M10x60x1.5. This is only used on the FST platform product line. 5/11/22 Quality and Production engineering screened all hardware at the production station. It was found that 90-08142 were mixed in with 90-08134. The hardware bins were clearly marked as 90-08134. Warehouse personnel inspected inventory of P/N 90-08134 and found P/N 90-8142 mixed in the box in the warehouse. Quality and Production engineering inspected the warehouse and found that boxes of 90-08134 and boxes of the 90-08142 were next to each other on the same shelf. Production engineering removed the remaining 90-08142 from inventory and moved them to the intended assembly station. The location for 90-08142 has also been moved to a different warehouse location to avoid future mix-ups. 5/11/22 Quality and Production engineering inspected all FST bikes still in WIP (production line). A second bike VIN#21642 was found to have the wrong bolt installed in one of the forks. VIN#21642 was removed from the production line and the fork was replaced. This second bike prompted Quality engineering to expand the investigation to a larger scope of FST bikes. 5/12/22 to 5/20/22 Warehouse bin fill log showed a gap in bin fill intervals back to 4/28/22. Quality engineering pulled all 65 FST bikes that went through station VB06 between 4/28/22 to 5/10/22. Of the 65 FST bikes inspected, one more FST bike VIN#21540 was found to have the incorrect bolt installed in one of the forks. Description of Remedy : Description of Remedy Program : Zero Motorcycles dealers will inspect and, if necessary, replace the front brake caliper bolts and forks on affected motorcycles. Dealers will then submit a warranty claim for the parts and labor related to the replacement. The labor time for inspection is .25 and replacement is 0.30 hours (per fork). Zero Motorcycles has not developed a separate reimbursement plan for this recall because all the 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 bolts (p/n 90-08142 – HEX FLANGE BOLT STAR DRIVE PER ZM 88-08813 M10X60 8.8 ZM-F-01 ZM-L-02) are 60mm long with course threads (1.5mm pitch). The correct bolts (p/n 90-08134 – HEX FLANGE BOLT STAR DRIVE PER ZM 88-08813 M10X55X1.25 THREAD 10.9 ZMF- 01 ZM-L-02) are 55mm long and with fine threads (1.25mm pitch). Identify How/When Recall Condition was Corrected in Production : Zero Motorcycles production and logistics teams removed the recalled bolts from the production line on May 11, 2022 and they were immediately replaced with the correct bolts. Additional inspection requirements were confirmed with the Final Quality Inspection team on May 12, 2022. Recall Schedule : Description of Recall Schedule : Zero Motorcycles expects to notify its dealer network no later than the Part 573 Safety Recall Report 22V-403 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 week of June 20, 2022 and motorcycle owners no later than the week of June 27, 2022. Planned Dealer Notification Date : JUN 20, 2022 – JUN 30, 2022 Planned Owner Notification Date : JUN 27, 2022 – JUL 05, 2022 * NR – Not Reported

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