- Only Zero DSR/X models manufactured between July 2022 and April 2023 are affected
- The cause is incorrectly specified fasteners in the motor controller
- The motor controller will be replaced free of charge at the dealer
According to Zero Motorcycles, the recall affects a very small number of DSR/X models from the 2023 model year. Nevertheless, the manufacturer considers the issue to be safety-related, as it could lead to unexpected drive failure while riding.
Reason for the recall
The recall focuses on the motor controller. Under certain circumstances, this may have been installed incorrectly. The reason for this is a material shortage during production, which resulted in the supplier using fasteners without a phosphate coating.
These screws have different friction properties than the originally intended variants. As a result, the preload on internal high-current connections may be lower than specified. This can lead to increased electrical resistance at the busbar connections, which in turn can trigger a power surge in the motor controller.
Possible effects during driving
If such a power surge occurs, the system’s protective function may be triggered and interrupt the flow of current. The result is a sudden loss of propulsion while driving. According to the manufacturer, there is no warning to indicate this condition.
An unexpected loss of power at the rear wheel can increase the risk of an accident. According to current findings, there have been documented cases of “quits while running” that did not result in accidents or personal injury. Nevertheless, the issue is classified as safety-relevant.
Affected vehicles and production period
According to the manufacturer, around seven motorcycles worldwide are affected. This corresponds to 100 percent of the DSR/X units produced during the period mentioned. The affected vehicles were manufactured between July 4, 2022, and April 21, 2023.
Motorcycles outside this period are not believed to be affected. Zero Motorcycles states that the problem has been rectified in ongoing production as soon as the material was available again and the correctly coated fasteners could be used.
Recall procedure and remedy
Zero Motorcycles will inform its dealer network about the recall between December 5 and 19, 2025. Vehicle owners will be notified between January 9 and 16, 2026. From this date onwards, affected motorcycles can be taken to an authorized dealer.
As part of the recall, the motor controller will be completely replaced. The new components have the correctly coated fasteners. In addition, an extended torque control is to be introduced at the supplier to ensure the correct preload on the high-current connections. There will be no cost to owners.
Recall also confirmed in Canada
In addition to the US, the recall has also been officially registered in Canada. The Canadian transportation authority describes the same issue and also refers to the possible loss of power at the rear wheel as a safety risk. Here, too, the remedy is to have the motor controller replaced by an authorized dealer.
Further information on the recall and the official classification can be found in the US Transportation Authority’s safety recall report.
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