Zero is issuing a recall on certain 2011-2012 models due to a problem with the brake light switches. The recall applies to the 2011-12 Zero DS, Zero S and Zero XU, the 2012 Zero X and the street-legal versions of the 2011 Zero MX and Zero X.
According to documents released by the National Highway Traffic Safety Administration, the front brake lever travel is too broad, and as a result may not activate the brake light under moderate application of the front brakes.
As a result, motorists traveling behind a Zero rider may not see the brake light turn on as the rider tries to slow down, increasing the risk of a crash.
The problem was first identified in March 2012 during an internal quality control audit. Zero’s customer service department noticed a brake lever needed to be squeezed further than expected before the brake light illuminated. Information was passed on to Zero’s engineering department which began its own investigation.
Zero then contacted its brake system supplier, Hayes Brakes of Mequon, Wisc. Zero and Hayes Brakes worked together on further testing to analyze the problem. In June, Zero completed an internal investigation and determined there was a defect. A new light switch was developed for the front brake lever.
Zero will notify owners about the recall and replace the brake light switch at no charge. The recall campaign affects 450 units.