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How did Americans discover the Zero's weak points?

Short answer

With a nearly intact example: Americans recovered an A6M2 on Akutan Island after the air attack on 4 June 1942. Its pilot, hit by anti-aircraft fire, attempted an emergency landing and the fighter flipped over on soft ground. Test flights at Naval Air Station North Island revealed its shortcomings.

How did Americans discover the Zero's weak points?
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The Akutan Zero

An A6M fighter was hit by anti-aircraft fire from the ground. Its pilot attempted an emergency landing on Akutan Island, about 20 miles (32 km) northeast of Dutch Harbor, but the Zero flipped over on soft ground in a sudden forced landing. He died instantly from head injuries: the tremendous impact broke his neck. Following that air attack on 4 June 1942, Americans recovered a largely intact A6M2 on Akutan.

Testing at North Island

Test flights at Naval Air Station North Island revealed both the strengths and the shortcomings of the design. The Zero's controls were very light at 200 mph (320 km/h), but stiffened above 216 mph (348 km/h) to protect the wing from structural failure. The tests also showed that the Zero could not roll to the right as quickly as to the left, something that could be exploited.

Exploitable weaknesses

Its low never-exceed speed (VNE) made it vulnerable in a dive. The difference between rolling one way and the other was flagged as an exploitable margin against the Japanese fighter. The stiffening of the controls above 216 mph (348 km/h) contrasted with their lightness at 200 mph (320 km/h).

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