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[RickSteeb]

THIS just in:

http://www.consumeraffairs.com/recalls/zero-motorcycles-recalls-s-and-ds-bikes-080913.html

"Zero Motorcycles is recalling 268 model year 2011 and 2012 S and DS motorcycles.

The front caliper mounting bolts are susceptible to corrosion which could lead to their cracking and possible fracture. If a front caliper bolt fractures, the caliper may come loose and interfere with the rotation of the front wheel. This could cause the front wheel to stop suddenly, increasing the risk of a crash

Zero Motorcycles will notify owners, and dealers will replace the front caliper bolts. The recall is expected to begin mid-August 2013.

Owners may contact Zero Motorcycles at 1-888-841-8085."

 

[trikester]

Well at least it's an easy fix, just replacing a couple of easily accessible bolts.

Trikester

[BSDThw]

So I am not the only one!

http://electricmotorcycleforum.com/boards/index.php?topic=2993.msg14462#msg14462

[firepower]

With so many recalls and EV bikes being new tech, maybe a new forum heading or sticky called recalls may be need. May save a lot of questions and first place to check after buying an EV bike.

@BSDthw , a very poor design of a critical part that should never rust or corrode, the bolt that the brake pads slide on. looks like the recall is for caliper bolts only.

[Richard230]

My bolts still look good, with no corrosion in evidence.  It kind of makes you wonder how failure-prone bolts could have been sourced for the caliper mounts?  Finding good bolts for a mount like this should be a snap.  Just specify the right type of bolt with the correct hardness and corrosion-resistance and order away from any of a number of hardware companies.     Of course, I might not be a good idea sourcing the bolts from Harbor Freight Tools in their "bargain bin" section.   

[BSDThw]

Sorry English is not my mother tongue what "bolts" are you talking off?

[Richard230]

I think they are the two bolts that fasten the caliper body to the flange cast onto the bottom of the front fork. Not something that you would want to break while you were riding.   

[BSDThw]

Tanks Richard, always nice to have a helping hand!

Hope nobody has had a real occurrence while riding

[Richard230]

This recall news has hit the Autoblog:  http://www.autoblog.com/2013/08/11/zero-s-ds-electric-motorcycle-recall/

[Richard230]

An hour ago there was a knock on my door. When I opened the door the the mail-lady was standing there and wanting me to sign for a certified letter from Zero requesting that I take my bike in to my dealer to have its caliper bolts replaced.  Nothing about the "glitch", though.

[ZeroSinMA]

An hour ago there was a knock on my door. When I opened the door the the mail-lady was standing there and wanting me to sign for a certified letter from Zero requesting that I take my bike in to my dealer to have its caliper bolts replaced.  Nothing about the "glitch", though.

The glitch won't kill you. A locked up front wheel at speed might.

[RickSteeb]

An hour ago there was a knock on my door. When I opened the door the the mail-lady was standing there and wanting me to sign for a certified letter from Zero requesting that I take my bike in to my dealer to have its caliper bolts replaced.  Nothing about the "glitch", though.

Got my registered letter this afternoon.  I emailed Mr Kenton to inquire whether the bolt R&R service had been performed during the three weeks my bike has been at the factory [for the glitch!] ...

[manlytom]

Hi all

So it says 268 bikes are affected. So is it just some of us? Number sounds rather low. On my part have not received a letter. And we don't have a dealer left to replace these bolts...
I have checked mine visually, all seems ok. But still don't know exactly which ones are subject to recall. Anyone have a better idea more details?

[benswing]

What happened is 2 bolts are made of the wrong material, so they corrode more than the bolts they are using to replace them.  Got mine replaced in 2 minutes.

The 2012 bikes that are affected are 1-99 (check your VIN).  Mine is 41, so they are now replaced.  I don't think anything more than extra corrosion has happened so far.

[Richard230]

So today I visited my Zero dealer with the idea that I could get the caliper bolts replaced as I waited, or maybe they would just give me the bolts and let me do it myself.  So much for that plan.  In spite of what the recall notice said, my dealer had no replacement bolt kits in stock.  They took my name and phone number and said they would call me back next week after the Zero factory is open so that they could order the bolts. They will let me know when they have arrived and then I can have the work performed. 

So the reason for this post is to advise anyone planning to have the recall work performed to call their dealer first and make sure that the bolt kits are actually in stock.