2009–2010 Zero DS, 2009–2010 Zero S Recall: Service Brakes, Hydraulic

The defect

ZERO MOTORCYCLES IS RECALLING CERTAIN MODEL YEAR 2009 ZERO S MOTORCYCLES BUILT FROM SEPTEMBER 2, 2009 THROUGH DECEMBER 22, 2009; MODEL YEAR 2009 ZERO DS MOTORCYCLES BUILT FROM JULY 27, 2009 THROUGH DECEMBER 28, 2009; MODEL YEAR 2010 ZERO S MOTORCYCLES BUILT FROM FEBRUARY 1, 2010 THROUGH MARCH 31, 2011; AND MODEL YEAR 2010 ZERO DS MOTORCYCLES BUILT FROM JANUARY 20, 2010 THROUGH MARCH 31, 2011. THE FRONT BRAKE CALIPER BRACKET MAY EXPERIENCE PERMANENT DEFORMATION WHEN SUBJECTED TO HIGH BRAKING LOADS. THIS CONDITION COULD INDUCE MISALIGNMENT OF THE FRONT BRAKE PADS WITH RESPECT TO THE FRONT BRAKE ROTOR.

The risk

MISALIGNMENT OF THE BRAKE PADS IN RELATION TO THE ROTOR MAY CAUSE REDUCED FRONT BRAKING PERFORMANCE, WHICH COULD LEAD TO A POSSIBLE CRASH AND POTENTIAL INJURY OR DEATH OF THE RIDER.

The fix — what to do

DEALERS WILL REPLACE THE FRONT BRAKE CALIPER BRACKET WITH A RE-DESIGNED COMPONENT, AND REPLACE THE FRONT BRAKE PADS IN CASE THE EXISTING PADS EXPERIENCED ABNORMAL WEAR. THE FRONT BRAKE FLUID WILL ALSO BE INSPECTED AND, IF SIGNS OF OVERHEATING ARE NOTED, IT WILL BE REPLACED AND THE SYSTEM WILL BE FLUSHED. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 31, 2011. OWNERS MAY CONTACT ZERO MOTORCYCLES AT 1-888-786-9376 EXT 45.

OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .