Incorrect Rear Brake Pads Installed – 2022 Zero SR, SR/F, & SR/S Motorcycles

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December 3, 2021 NHTSA CAMPAIGN NUMBER: 21V940000

Incorrect Rear Brake Pads Installed/FMVSS 122

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 ownerโ€™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 ABSeBay. 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 (โ€œFQCโ€) 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

MAKEMODELYEAR
ZEROSR2022
ZEROSR/F2022
ZEROSR/S2022

 


8 Associated Documents

Recall Acknowledgement

RCAK-21V940-9976.pdf 645.097KB

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Noncompliance Notice 573 Report

RCLRPT-21V940-2611.PDF 216.252KB

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Recall 573 Report-Amendment 1

RCLRPT-21V940-5360.PDF 216.253KB

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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

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V940-0085.pdf 110.669KB

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Recall Quarterly Report #1, 2022-1

RCLQRT-21V940-9489.PDF 211.149KB

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Recall Quarterly Report #2, 2022-2

RCLQRT-21V940-5640.PDF 211.248KB

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Recall Quarterly Report #3, 2022-3

RCLQRT-21V940-6359.PDF 211.329KB

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