Tesla will be recalling the Roadster 2.0 and 2.5 due to a fire hazard.

The issue is that the 12V low voltage auxilary cable, located behind the passenger side headlamp, can chaff against a carbon fibre panel, resulting in a short circuit, smoke, and possibly fire.

Only one case of this happening has been recorded, but Tesla deemed this enough to issue a voluntary recall. 439 cars are affected. Roadster 1.5 models are not involved in the recall, as they did not come with the cable in question.

Press Release

Tesla Initiates Voluntary Recall After Single Customer Incident

Friday, October 1, 2010

Palo Alto, Calif. — Tesla Motors has launched a voluntary safety recall on Roadster models 2.0 and 2.5. The recall involves the 12v low voltage auxiliary cable from a redundant back up system that provides power to various systems, including the headlamps, taillights, turn signals and hazard lights, and airbags in the unlikely event the primary 12V power fails or drops below a minimum threshold value.

Located forward of the passenger side front wheel, behind the headlamp, the 12v low voltage auxiliary cable is physically isolated from the main battery pack in the rear of the car.

Tesla decided to initiate a recall after the low voltage auxiliary cable in a single vehicle chafed against the edge of a carbon fiber panel in the vehicle causing a short, smoke and possible fire behind the right front headlamp of the vehicle. This issue is limited to the 12V low voltage auxiliary cable and does not involve the main battery pack or main power system.

Once aware of this single incident, Tesla quickly determined that a voluntary recall was an appropriate precautionary measure. The recall affects 439 Roadsters.

Tesla has made corresponding regulatory agencies aware of the discovery and has already initiated a correction in customer cars. The correction involves checking the routing of the 12V low voltage auxiliary cable and installing a protective sleeve over it. Tesla’s Service team has started notifying customers via email and has initiated a mailing campaign. Tesla Service Rangers can perform the service at customers’ homes or offices. The service takes approximately one hour.

This recall does not impact earlier Roadster 1.5 vehicles (VIN ending with 500 or before) as these cars do not include the 12V auxiliary cable in question.

About Tesla Motors

Tesla’s goal is to produce increasingly affordable electric cars to mainstream buyers – relentlessly driving down the cost of EVs. Palo Alto, Calif.-based Tesla has delivered more than 1300 Roadsters to customers in North America, Europe and Asia. Tesla designs and manufactures EVs and EV powertrain components. It is currently the only automaker in the U.S. that builds and sells highway-capable EVs in serial production. The Tesla Roadster accelerates faster than most sports cars yet produces no emissions.

Source: Tesla