NHTSA ID Number: 10200059
Manufacturer Communication Number: SV-ZMC-020-413
TSB/Document Date: 2021-08-21
Summary
Model Year 2020 Zero SR/F Tank Trunk Lid Upgrade Offer - Zero Motorcycles is announcing an upgrade offer whereby owners of Zero SR/F motorcycles produced prior to August 13, 2019 can have the tank trunk lid upgraded by their dealer, and Zero will cover the cost of parts and labor in that replacement.
Dealer
Sales
Operator/
New
General
Vehicles
Manager
Date:
September 30, 2019
Sales
Used
Vehicles
Business
Manager
(F&I)
Service
Source: Zero Motorcycles Customer
Experience Department
Parts &
Accessories
Administration
Program Period: Commencing
November 1, 2019
Model Year 2020 Zero SR/F
Tank Trunk Lid Upgrade Offer
Overview
Zero Motorcycles is announcing an upgrade offer whereby owners of Zero SR/F motorcycles produced
prior to August 13, 2019 can have the tank trunk lid upgraded by their dealer, and we will cover the cost of
parts and labor in that replacement. We recognize that the fit between the tank trunk lid and the tank was
not perfect, and so we are taking steps to correct this issue. We believe that Zero motorcycles should stand
up to the highest level of scrutiny, and we are confident that every owner’s motorcycle will be able to do that
following this upgrade.
We will announce this upgrade offer to owners on September 30, 2019. Replacement tank trunk lids will
become available in November 2019. Where an existing demonstrator motorcycles is still available for sale
at a dealer, Zero Motorcycles will ship a replacement tank trunk lid to the dealer. We encourage dealers to
pre-order the replacement tank trunk lids to have them in stock when owners arrive with their motorcycles.
Please email you order to [email protected] in the Americas or [email protected] in
the EMEA region.
Applicable Models
All 2020 Zero SR/F motorcycles manufactured before August 13, 2019.
Tools Required
7mm Socket and Ratchet
3mm Hex Ball End Driver
#2 Phillips Head Screwdriver
Flat Head Screwdriver
TORX T25 Screwdriver
Parts Required
Order one of the following depending on the color of the motorcycle:
24-08597-30 – TANK TRUNK LID ASSEMBLY BOARDWALK RED
24-08597-31 – TANK TRUNK LID ASSEMBLY SEABRIGHT BLUE
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-020-413
Dealer
Sales
Operator/
New
General
Vehicles
Manager
Date:
September 30, 2019
Sales
Used
Vehicles
Business
Manager
(F&I)
Service
Source: Zero Motorcycles Customer
Experience Department
Parts &
Accessories
Administration
Program Period: Commencing
November 1, 2019
Process Steps
1. Confirm that you have all required tools and parts before starting the installation.
2. Remove tank assembly from motorcycle by first removing the four M5x16 hex flange star drive bolts using
the 7mm socket and ratchet. Then, remove the two M5x8 hex socket button head screws on the Tank Arm
Outer Lower piece using the 3mm hex ball end driver. See pictures below.
3. Using the #2 Philips head screwdriver, remove the seven Phillips head screws from the inside of the Tank
Arm Outer Left to detach it from the tank assembly. Retain all parts for reassembly.
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-020-413
Dealer
Sales
Operator/
New
General
Vehicles
Manager
Date:
September 30, 2019
Sales
Used
Vehicles
Business
Manager
(F&I)
Service
Source: Zero Motorcycles Customer
Experience Department
Parts &
Accessories
Administration
Program Period: Commencing
November 1, 2019
4. Repeat this process of removing the seven Phillips head screws from the inside of the Tank Arm Outer
Right to detach it from the tank assembly. Retain all parts for reassembly.
5. Open the Tank Trunk Lid Assembly to relieve the strain on the springs. Note the orientation of the two
different torsion springs on the inside. See picture below.
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-020-413
Dealer
Sales
Operator/
New
General
Vehicles
Manager
Date:
September 30, 2019
Sales
Used
Vehicles
Business
Manager
(F&I)
Service
Source: Zero Motorcycles Customer
Experience Department
Parts &
Accessories
Administration
Program Period: Commencing
November 1, 2019
6. The motorcycle may have one of two different pin types. Most will have an integrated snap as shown in on
the top pin in the picture below. However, some will have an e-clip as shown in the bottom pin in the picture
below. Depending on the pin type, remove the both springs by pressing on the snaps of the pins with a flat
head screwdriver, or removing the e-clip, and pulling them out one at a time. If you have the snap-type pin,
the pin will stop at the tank trunk lid pivot point. Retain the springs for reassembly.
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-020-413
Dealer
Sales
Operator/
New
General
Vehicles
Manager
Date:
September 30, 2019
Sales
Used
Vehicles
Business
Manager
(F&I)
Service
Source: Zero Motorcycles Customer
Experience Department
Parts &
Accessories
Administration
Program Period: Commencing
November 1, 2019
7. If you have the snap-type pin, align the snap of the pins to face you. Then, press the snaps again with a
flat head screwdriver and pull each out to release from the tank trunk lid assembly. Then, pull pins to release
the washer. Retain the pins, e-clips and washers for reassembly.
8. Using a TORX T25 screwdriver, detach Tank Trunk Latch Loop by unscrewing the M5x16 hex flange star
drive bolts. Retain the latch loop and bolts for reassembly.
9. Install the Tank Trunk Latch Loop on the new Tank Trunk Lid Assembly using the M5x16 hex flange star
drive bolts. Tighten to hand tight.
10. Install the pin, e-clip (if it wasn’t a snap-type pin), washer and spring on each side of the Tank Trunk Lid
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-020-413
Dealer
Sales
Operator/
New
General
Vehicles
Manager
Date:
September 30, 2019
Sales
Used
Vehicles
Business
Manager
(F&I)
Service
Source: Zero Motorcycles Customer
Experience Department
Parts &
Accessories
Administration
Program Period: Commencing
November 1, 2019
Assembly to reattach it to the tank assembly. We recommend installing one spring first and then the other.
Refer to the original orientation to ensure they are installed on the correct sides.
11. Reattach the Tank Arm Outer Left and then Right to the tank assembly using the #2 Phillips head
screwdriver and the retained Phillips head screws. Tighten to hand tight and take care not to overtighten.
12. Reattach the tank assembly to the motorcycle using the existing M5x16 hex flange star drive bolts and
the M5x8 hex socket button head screws. Pictures shown in step #2 of these instructions.
13. Open and close the tank trunk lid assembly to confirm proper fitment.
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-020-413
Dealer
Sales
Operator/
New
General
Vehicles
Manager
Date:
September 30, 2019
Sales
Used
Vehicles
Business
Manager
(F&I)
Service
Source: Zero Motorcycles Customer
Experience Department
Parts &
Accessories
Administration
Program Period: Commencing
November 1, 2019
Timing and Reimbursement
To receive reimbursement for the work performed and parts used under this upgrade offer, the dealer must
submit a goodwill warranty claim for the replacement costs incurred that includes the following information:
• Fault Summary: MY20 Zero SR/F Tank Trunk Lid Upgrade Offer
• Fault Area: 24-Bodywork
• Fault Code: 90-Service Bulletin Campaign
• Service Bulletin / Recall: MY20 Zero SR/F Tank Trunk Lid Upgrade Offer
• Warranty Claim Type: Goodwill
See example below for full details.
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 loaner or temporary replacement motorcycles or other vehicles.
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-020-413
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TSB/Document ID: SV-ZMC-020-413
Replacement Service Bulletin Number:
MFR Communication Date: 2019-09-30
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: UNKNOWN OR OTHER
MFR Component System:
MFR Component Subsystem:
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