- 118 motorcycles of the DS, DSR, DSRP, and DSR/X models affected
- Production period: March 19, 2024, to May 29, 2025
- Free inspection and repair at the dealer
Several Zero Motorcycles models from the 2024 and 2025 model years are affected by an official recall. The affected vehicles may have a faulty brake line on the front brake. In certain cases, the line is said to have been twisted by approximately 180 degrees during assembly, which can lead to damage in the long term.
Reason for the recall
According to Zero Motorcycles Inc., the cause is an assembly error on the production line. The brake line that runs from the ABS hydraulic control unit to the front brake calipers may have been installed twisted in some vehicles.
This misalignment restricts the intended mobility of the line. This can result in increased friction at attachment points such as the P clamp. This friction can damage the outer layers of the line and subsequently cause a loss of brake fluid.
Possible impact on driving safety
A brake fluid leak can lead to a gradual or sudden loss of brake pressure on the front brake. This can significantly reduce braking performance. Zero Motorcycles points out that this can increase the risk of losing control of the motorcycle.
To date, there has been one known incident in Europe in which a rider is said to have lost control of their motorcycle as a result of this problem. No injuries have been reported in connection with this incident.
Affected models and quantities
The recall affects a total of 118 motorcycles of the following models and model years (US market):
- Zero DS model year 2024: 14 vehicles
- Zero DS model year 2025: 25 vehicles
- Zero DSR model year 2024: 15 vehicles
- Zero DSR model year 2025: 9 vehicles
- Zero DSRP model year 2024: 24 vehicles
- Zero DSRP model year 2025: 7 vehicles
- Zero DSR/X model year 2024: 1 vehicle
- Zero DSR/X model year 2025: 23 vehicles
All affected motorcycles were produced between March 19, 2024, and May 29, 2025. Zero estimates that around 30 percent of the vehicles could actually be affected by the defect.
Investigation process
The first indications of the problem were received in December 2024, when two warranty claims involving leaking brake lines were reported. Due to the small number of cases, the situation was initially monitored.
In June 2025, further reports followed, including several from Europe. Zero then launched a comprehensive investigation. In July 2025, the internal Product Integrity Team finally recommended a voluntary safety recall.
In January 2026, the recall was extended again after vehicles outside the originally defined VIN range also showed abnormalities.
Technical shutdown in production
Zero Motorcycles introduced a change in the production process on July 28, 2025. A mechanical device known as a poka-yoke is now used to prevent incorrect installation of the brake line. Motorcycles manufactured after this date are not part of the recall.
Recall measures and dates
Authorized Zero dealers will inspect the affected motorcycles. The front brake line will be checked for twists and damage. If a fault is found, the line will be replaced and correctly routed. The work is free of charge for owners.
Dealers will be notified between February 4 and 6, 2026. Owners of affected motorcycles are expected to receive notification between February 23 and 27, 2026. Starting February 27, 2026, the affected vehicle identification numbers will also be available in the National Highway Traffic Safety Administration database.
Contact and further information
If owners have any questions about the recall, they can contact Zero Customer Service at 1 888 841 8085. The internal recall number is SV RCL 025 017.2. This information applies to the US.
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