Photo: Zero Motorcycles
Based in Scotts Valley, the peeps at Zero Motorcycles are calling back a grand total of 23 bikes from the SR lineup. More specifically, 2022 models produced between April 22nd and April 27th of this year. The street-oriented SR and more powerful SR/F are called back to replace the front brake caliper bolts.
Back on May 11th, the production engineering department alerted quality engineering of an issue on the assembly line. Zero explains that a front brake caliper bolt would not install properly. Subsequent investigation revealed that an incorrect bolt was being used, similar in appearance to the good one but five millimeters longer. The wrong bolt further features coarse threads.
When installed in the SR or SR/F, the suspect bolt damages the mating threads inside the bike’s forks. Quality and production engineering then screened all the hardware at the production station, discovering that wrong bolts were mixed with correct bolts in the hardware bins. Warehouse personnel then realized that boxes labeled with the correct brake caliper bolt’s part number were stored right next to boxes full of incorrect bolts.
As expected, warehouse personnel then moved the boxes to different locations to avoid future mix-ups. On the very same date, all of the motorcycles on the assembly line were inspected in great detail. Zero identified a second motorcycle with the wrong bolt installed, prompting the quality engineering peeps to expand the investigation to a larger scope.
The warehouse bin log showed a gap in fill intervals back to April 28th, which is why 65 motorcycles produced between April 28th and May 5th were thoroughly inspected. One of them was found to have the incorrect bolt.
Owners of the 23 bikes mentioned earlier will be notified of the recall in the week starting June 27th. Dealers, on the other hand, will be informed of the recall this week. The labor time for inspection is 15 minutes and replacement of the incorrect bolts should take circa 30 minutes per fork.
When installed in the SR or SR/F, the suspect bolt damages the mating threads inside the bike’s forks. Quality and production engineering then screened all the hardware at the production station, discovering that wrong bolts were mixed with correct bolts in the hardware bins. Warehouse personnel then realized that boxes labeled with the correct brake caliper bolt’s part number were stored right next to boxes full of incorrect bolts.
As expected, warehouse personnel then moved the boxes to different locations to avoid future mix-ups. On the very same date, all of the motorcycles on the assembly line were inspected in great detail. Zero identified a second motorcycle with the wrong bolt installed, prompting the quality engineering peeps to expand the investigation to a larger scope.
The warehouse bin log showed a gap in fill intervals back to April 28th, which is why 65 motorcycles produced between April 28th and May 5th were thoroughly inspected. One of them was found to have the incorrect bolt.
Owners of the 23 bikes mentioned earlier will be notified of the recall in the week starting June 27th. Dealers, on the other hand, will be informed of the recall this week. The labor time for inspection is 15 minutes and replacement of the incorrect bolts should take circa 30 minutes per fork.
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