Zero Motorcycles Inc. (Zero) is recalling certain 2024 DSR/X, DS, DSR, and DSRP motorcycles. The front brake hose may be twisted and become damaged, which can cause a brake fluid leak and a loss of brake pressure.

Risk: A loss of brake pressure will reduce braking ability, increasing the risk of a crash.

2021 ZERO DS

64 vehicles affected

20V640000

ELECTRICAL SYSTEM:PROPULSION SYSTEM:DC/DC CONVERTER

Zero Motorcycle Inc. (Zero) is recalling certain 2021 SR, S, DSR, DS, FX, and FXS motorcycles. The DC-DC converter has an insufficient power output margin to operate the anti-lock braking system (ABS), instruments, lights, indicators, and any accessories that are connected to the accessory outlet at once.

Risk: The DC-DC converter can shut off when its power capacity is exceeded, shutting off the ABS, instruments, and lights, increasing the risk of a crash.

2018 ZERO DS

36 vehicles affected

17V762000

EQUIPMENT:OTHER:LABELS

Zero Motorcycles Inc. (Zero) is recalling certain 2018 S ZF13.0, S ZF7.2, SR ZF14.4, DS ZF13.0, DSR ZF14.4, FX ZF7.2, and FXS ZF7.2 motorcycles. The information on the Vehicle Emission Control Information (VECI) Label may indicate the wrong model year. As such, these vehicles fail to comply with the requirements of 49 CFR Part 567, "Certification."

Risk: If the affected 2018 motorcycles are ever subject to a recall, the owner may not realize the safety risk because of the misstated model year.

2017 ZERO DS

61 vehicles affected

17V145000

SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

Zero Motorcycles Inc. (Zero) is recalling certain 2017 S, DS, and FXS motorcycles. The Anti-Lock Braking System (ABS) Hydraulic Control Unit (HCU) may have the wrong vehicle model information, possibly causing the ABS to function improperly.

Risk: If the ABS does not function properly in a braking event, there is an increased risk of a crash.

2015 ZERO DS

96 vehicles affected

16V610000

SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

Zero Motorcycles Inc. (Zero) is recalling certain model year 2015 SR, S, DS, and FX motorcycles. The affected motorcycles have a DC-DC converter that may have insufficient output power. During high power demand, the anti-lock brake system (ABS) may not function properly.

Risk: If the converter power output is insufficient, during an ABS activated event, the ABS and all vehicle lights would temporarily stop functioning, increasing the risk of a crash.

2014 ZERO DS

94 vehicles affected

14V119000

ENGINE AND ENGINE COOLING:ENGINE

Zero Motorcycles, Inc. (Zero) is recalling certain model year 2014 Zero SR motorcycles manufactured December 30, 2013, through February 20, 2014, 2014 Zero S motorcycles manufactured December 26, 2013, through February 18, 2014, Zero DS motorcycles manufactured January 24, 2013, through February 4, 2014, and 2014 Zero FX motorcycles manufactured January 14, 2014, through January 27, 2014. Due to a possible manufacturing defect, the motor rotor may contact the stator while riding.

Risk: If the rotor contacts the stator, the motor could seize, locking up the rear wheel which could increase the risk of a crash.

2013 ZERO DS

667 vehicles affected

13V635000

ELECTRICAL SYSTEM:SOFTWARE

Zero Motorcycles Inc. (Zero) is recalling certain model year 2012-2013 XU, S, DS, and model year 2013 FX motorcycles. The affected motorcycles have controller firmware that, as a result of certain system faults, may shut off power to the motor.

Risk: A sudden loss of power to the motor may increase the risk of a crash.

2011 ZERO DS

268 vehicles affected

13V329000

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER

Zero Motorcycles is recalling certain model year 2011 and 2012 S and DS motorcycles. On the affected motorcycles, the front caliper mounting bolts are susceptible to corrosion which could lead to their cracking and possible fracture.

Risk: 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.

2011 ZERO DS

450 vehicles affected

12V307000

EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH

ZERO MOTORCYCLES, INC. (ZERO) IS RECALLING CERTAIN MODEL YEAR 2011 AND 2012 S, XU, AND DS MOTORCYCLES, MODEL YEAR 2011 MXD, AND XD MOTORCYCLES AND 2012 X MOTORCYCLES. THE BRAKE LIGHT SWITCH AT THE FRONT BRAKE LEVER MAY NOT ACTIVATE UNTIL SIGNIFICANT BRAKE LEVER TRAVEL OCCURS.

Risk: THE BRAKE LIGHT MAY NOT ACTIVATE WHEN A MODERATE AMOUNT OF FRONT BRAKE IS APPLIED. AS SUCH, MOTORISTS TRAVELING BEHIND THE MOTORCYCLE MAY NOT BE ALERTED WHEN AN AFFECTED MOTORCYCLE IS SLOWING DOWN, WHICH COULD LEAD TO A POSSIBLE CRASH AND POTENTIAL INJURY OR DEATH TO THE RIDER.

2009 ZERO DS

160 vehicles affected

11V282000

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:PADS

ZERO MOTORCYCLES IS RECALLING CERTAIN MODEL YEAR 2009 ZERO S MOTORCYCLES BUILT FROM SEPTEMBER 2, 2009 THROUGH DECEMBER 22, 2009; MODEL YEAR 2009 ZERO DS MOTORCYCLES BUILT FROM JULY 27, 2009 THROUGH DECEMBER 28, 2009; MODEL YEAR 2010 ZERO S MOTORCYCLES BUILT FROM FEBRUARY 1, 2010 THROUGH MARCH 31, 2011; AND MODEL YEAR 2010 ZERO DS MOTORCYCLES BUILT FROM JANUARY 20, 2010 THROUGH MARCH 31, 2011. THE FRONT BRAKE CALIPER BRACKET MAY EXPERIENCE PERMANENT DEFORMATION WHEN SUBJECTED TO HIGH BRAKING LOADS. THIS CONDITION COULD INDUCE MISALIGNMENT OF THE FRONT BRAKE PADS WITH RESPECT TO THE FRONT BRAKE ROTOR.

Risk: MISALIGNMENT OF THE BRAKE PADS IN RELATION TO THE ROTOR MAY CAUSE REDUCED FRONT BRAKING PERFORMANCE, WHICH COULD LEAD TO A POSSIBLE CRASH AND POTENTIAL INJURY OR DEATH OF THE RIDER.

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