Zero Motorcycles initiated a recall campaign on some 2009-2010 Zero S and Zero DS motorcycles due to a problem with the front brake.
According to documents released by the National Highway Traffic Safety Administration, the front brake caliper brackets on the affected motorcycles may become deformed under high braking loads. A deformed bracket may prevent the brake pads from lining up properly with the rotor, reducing braking efficiency.
The problem was first reported in August 2010 by a journalist testing a 2010 Zero S. At the time, Zero determined the problem was caused by a shifted seal in the front brake master cylinder. Later that month, Zero received a warranty case on a Zero S regarding brake fade. In September 2010, Zero opened an internal investigation about brake fade concerns and alerted the brake manufacturer. In the ensuing months, Zero received further reports about brake problems and in February 2011, a dealer reported a bent brake caliper bracket on a 2009 Zero S. Zero completed its internal investigation in April 2011 and confirmed the bracket could experience deformation.
Zero dealers will replace the front brake caliper bracket on affected units with a newly designed component at no charge. Front brake pads may also be replaced if they show signs of abnormal wear. Dealers will also inspect the front brake fluid and flush the system and replace the fluid if they note signs of overheating.
The recall campaign affects 160 motorcycles including 2009 Zero S models built Sept. 2 2009 – Dec. 22, 2009, 2009 Zero DS models built July 27, 2009 – Dec. 28, 2009, 2010 Zero S models built Feb. 1, 2010 – March 31, 2011 and 2010 Zero DS models built Jan. 20, 2010 – March 31, 2011.