October 13, 2021 NHTSA CAMPAIGN NUMBER: 21V795000
Rear Rotor Bolts Insufficiently Tightened
The loose bolts may damage the caliper or swingarm, reducing rear braking capability and increasing the risk of a crash.
NHTSA Campaign Number: 21V795
Manufacturer Zero Motorcycles Inc.
Components SERVICE BRAKES, HYDRAULIC
Potential Number of Units Affected 411
Summary
Zero Motorcycles Inc. (Zero) is recalling certain 2020 SR/F motorcycles. The rear rotor bolts were insufficiently tightened.
Remedy
Dealers will correctly tighten and replace the rear rotor bolts as necessary, free of charge. Owner notification letters were mailed November 1, 2021. Owners may contact Zero customer service at 1-888-841-8085. Zero’s number for this recall is SV-ZMC-020-417.
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.
Model Year 2020 Zero SR/F Rear Rotor Bolts
Re-Torque Service Recall
NHTSA Campaign Number: 21V-795
Purpose
Zero Motorcycles has determined that a defect, which relates to motor vehicle safety, exists on certain model year 2020 SR/F model motorcycles built between April 10, 2019 and December 19, 2019. The rear rotor bolts on the subject motorcycles were insufficiently torqued. Owners of these motorcycles may find that one or more of these bolts may back out of their sockets slowly and scratch or damage the caliper arm or swingarm of their motorcycles, which results in objectionable noise while riding. Should an owner fail to recognize the damage or respond to the noise, the bolt might be damaged to the extent that the rear braking capability would be reduced. This condition could increase the risk of a crash.
In the interest of motor vehicle safety and customer satisfaction, Zero Motorcycles has elected to initiate a voluntary safety recall (Campaign 21V-795) to remedy this defect. The remedy for this defect is to have Zero Motorcycles dealers re-torque the rear rotor bolts to 26 ft-lbs/36 Nm. If there is no damage to the bolts when re-torqued, the rear rotor bolts do not need to be replaced and the existing lock patch will secure them in place. If the bolts are damaged or removed first, then the dealer will replace them free of charge to the owner.
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 411 motorcycles includes all model year 2020 Zero SR/F motorcycles
manufactured before December 19, 2019. The last five digits of the vehicle identification number of affected motorcycles will be 13511 or lower. This population includes those motorcycles that have already been addressed by the Model Year 2020 Zero SR/F Rear Rotor Bolt Re-Torque Service Campaign. If a motorcycle was already reworked under that service campaign, no further action is necessary on that motorcycle.
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 safety-related 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
Torque Wrench (capable of 26 ft-lbs/36 Nm)
Parts Required
None.
However, if the rear rotor bolts are damaged in the process or removed prior to re-torquing them, please replace with the following part number:
90-08259 – STAR DRIVE BUTTON HEAD SCREW M8X20 W/ PRE-APPLIED LOCK PATCH
Procedure
- Confirm that you have all required tools and parts before starting this re-torque process. The rear rotor bolts only need to be replaced if they are damaged or have been removed, which strips the pre-applied lock patch.
- Lift the rear wheel using a rear paddock stand or other suitable method.
CAUTION: Do not lift the Zero SR/F by placing a scissor jack or other lift under the controller carrier
. Lifting the motorcycle in this manner could result in damage to the controller and other components.
- Using the T40 Star Drive Bit Socket and a Torque Wrench, re-torque the existing rotor bolts one at a time to 26 ft-lbs/36 Nm. The existing paint pen marks should reflect that the head of the bolt has rotated in this process.
- If any of the rear rotor bolts is damaged or is removed first, it should be replaced. Remove such bolts one at a time and replace. Torque each bolt to the 26 ft-lbs/36 Nm.
- Once all five rotor bolts have been re-torqued or replaced, lower the rear wheel of the motorcycle.
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: MY20 Zero SR/F Rear Rotor Bolt Re-Torque Recall
- Fault Area: 25-Brake
- Fault Code: 90-Service Bulletin Recall
- Service Bulletin / Recall: MY20 Zero SR/F Rear Rotor Bolt Re-Torque 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 20 minutes (0.33 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:
You will find the matching case it the Open Service Notification list.
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
SV-ZMC-020-417 Rev 2
Chronology :
Zero Motorcycles received notification of one instance of damage caused by a rear rotor bolt backing out of its socket on MY20 Zero SR/F motorcycles in September 2019, and an additional two in October 2019. All of these vehicles were deployed as demonstrator vehicles in Europe. One of these was a demonstrator vehicle still owned Zero Motorcycles BV at the time of the report.
As a result of these reports, Zero Motorcycles investigated the bolts used, the production processes and torque values. We confirmed that all bolts were installed using Loctite and were being torqued to 10 ft-lbs, which was the specified torque value. As a result of our review, we concluded that the torque was insufficient, and we increased our specification to 26 ft-lbs. This change in manufacturing process was implemented on December 19, 2019.
On January 20, 2020, Zero Motorcycles initiated a service campaign and notified dealers and owners of the torque value change. The company has been conducting an ongoing service campaign since that date. During this time, only one additional motorcycle was reported as having a rear rotor bolt back out in January 2021.
On October 7, 2021, the Product Integrity Team at Zero met to review the history of the original service campaign as requested by the National Highway Traffic Safety Administration (NHTSA). Based on this meeting, this team concluded that, if the warnings preceding this condition were to be missed by the rider, it could become a safety concern, and recommended the company take steps to voluntarily pursue a safety recall.
Zero Motorcycles is not aware of any accidents or injuries caused by this defect.
1 Affected Product
Vehicle
| MAKE | MODEL | YEAR |
| ZERO | SR/F | 2020 |
9 Associated Documents
Recall Acknowledgement
Defect Notice 573 Report
RCLRPT-21V795-6378.PDF 216.062KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V795-3318.pdf 275.392KB
Recall Quarterly Report #1, 2021-4
RCLQRT-21V795-4517.PDF 211.149KB
Recall 573 Report-Amendment 1
RCLRPT-21V795-1124.PDF 216.237KB
Manufacturer Notices(to Dealers,etc) – SV-ZMC-020-417-02 – 2020 Zero SRF Rear Rotor Bolts Re-Torque Recall
RCMN-21V795-2725.pdf 315.278KB
Recall Quarterly Report #2, 2022-1
RCLQRT-21V795-0346.PDF 211.249KB
Recall Quarterly Report #3, 2022-2
RCLQRT-21V795-8201.PDF 211.335KB
Recall Quarterly Report #4, 2022-3
RCLQRT-21V795-4024.PDF 211.439KB
Latest Recalls Documents
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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#538ZFAZ71LCK11813 Recall SV-ZMC-020-417 / NHTSA Recall #21V-795 AARON HUGHES 6501 Red Hook Plz Ste 201-864 St Thomas, VI 00802 November 1, 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 determined that a defect, which relates to motor vehicle safety, exists on certain model year 2020 SR/F model motorcycles built between April 10, 2019 and December 19, 2019. The rear rotor bolts on the subject motorcycles were insufficiently torqued. Owners of these motorcycles may find that one or more of these bolts may back out of their sockets slowly and scratch or damage the caliper arm or swingarm of their motorcycles. This condition would result in objectionable noise while riding and could eventually lead to the reduction of rear braking capability, which could increase the risk of 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 re-torque the rear rotor bolts to 26 ft-lbs/36 Nm. If there is no damage to the bolts when re-torqued, the rear rotor bolts do not need to be replaced and the existing lock patch will secure them in place. If the bolts are damaged or removed first, then the dealer will replace them at no charge to you. Should you choose to ride your suspect motorcycle prior to having your dealer perform this rework, you should be aware of this condition and perform a “pre-ride inspection” of these bolts and/or as specified in Zero Motorcycles Owners’ Manuals, you should re-torque the rear rotor bolts to 26 ft-lbs/36 Nm. Please contact your Zero Motorcycles dealer immediately and arrange an appointment to have your motorcycle repaired. The actual dealer labor time to perform this service will be approximately 30 minutes; however, due to scheduling, the dealer may require your motorcycle for a longer period. Zero Motorcycles Inc., 380 El Pueblo Rd, Scotts Valley, California, USA 95066 (831) 438-3500 – www.zeromotorcycles.com The parts and labor will be free of charge to you. Replacement parts are now available for order by your dealer. 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: October 18, 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-020-417 Rev 2 Model Year 2020 Zero SR/F Rear Rotor Bolts Re-Torque Service Recall NHTSA Campaign Number: 21V-795 Purpose Zero Motorcycles has determined that a defect, which relates to motor vehicle safety, exists on certain model year 2020 SR/F model motorcycles built between April 10, 2019 and December 19, 2019. The rear rotor bolts on the subject motorcycles were insufficiently torqued. Owners of these motorcycles may find that one or more of these bolts may back out of their sockets slowly and scratch or damage the caliper arm or swingarm of their motorcycles, which results in objectionable noise while riding. Should an owner fail to recognize the damage or respond to the noise, the bolt might be damaged to the extent that the rear braking capability would be reduced. This condition could increase the risk of a crash. In the interest of motor vehicle safety and customer satisfaction, Zero Motorcycles has elected to initiate a voluntary safety recall (Campaign 21V-795) to remedy this defect. The remedy for this defect is to have Zero Motorcycles dealers re-torque the rear rotor bolts to 26 ft-lbs/36 Nm. If there is no damage to the bolts when re-torqued, the rear rotor bolts do not need to be replaced and the existing lock patch will secure them in place. If the bolts are damaged or removed first, then the dealer will replace them free of charge to the owner. 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 411 motorcycles includes all model year 2020 Zero SR/F motorcycles manufactured before December 19, 2019. The last five digits of the vehicle identification number of affected motorcycles will be 13511 or lower. This population includes those motorcycles that have already been addressed by the Model Year 2020 Zero SR/F Rear Rotor Bolt Re-Torque Service Campaign. If a motorcycle was already reworked under that service campaign, no further action is necessary on that motorcycle. 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 safety-related condition and instructing them to contact their dealer for the associated remedy. Zero will also try to contact these customers via email. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: October 18, 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-020-417 Rev 2 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 T40 Star Drive Bit Socket Torque Wrench (capable of 26 ft-lbs/36 Nm) Parts Required None. However, if the rear rotor bolts are damaged in the process or removed prior to re-torquing them, please replace with the following part number: 90-08259 – STAR DRIVE BUTTON HEAD SCREW M8X20 W/ PRE-APPLIED LOCK PATCH Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: October 18, 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-020-417 Rev 2 Procedure 1. Confirm that you have all required tools and parts before starting this re-torque process. The rear rotor bolts only need to be replaced if they are damaged or have been removed, which strips the pre-applied lock patch. 2. Lift the rear wheel using a rear paddock stand or other suitable method. CAUTION: Do not lift the Zero SR/F by placing a scissor jack or other lift under the controller carrier. Lifting the motorcycle in this manner could result in damage to the controller and other components. 3. Using the T40 Star Drive Bit Socket and a Torque Wrench, re-torque the existing rotor bolts one at a time to 26 ft-lbs/36 Nm. The existing paint pen marks should reflect that the head of the bolt has rotated in this process. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: October 18, 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-020-417 Rev 2 4. If any of the rear rotor bolts is damaged or is removed first, it should be replaced. Remove such bolts one at a time and replace. Torque each bolt to the 26 ft-lbs/36 Nm. 5. Once all five rotor bolts have been re-torqued or replaced, lower the rear wheel of the motorcycle. 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: MY20 Zero SR/F Rear Rotor Bolt Re-Torque Recall • Fault Area: 25-Brake • Fault Code: 90-Service Bulletin Recall • Service Bulletin / Recall: MY20 Zero SR/F Rear Rotor Bolt Re-Torque 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 20 minutes (0.33 hours). We do not reimburse any costs related to towing or loaner/temporary replacement motorcycles/vehicles. Dealer Operator/ General Manager Sales New Vehicles Sales Used Vehicles Business Manager (F&I) Service Parts & Accessories Administration Date: October 18, 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-020-417 Rev 2 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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