Zero Motorcycles recalls

Affected motorcycles may have been produced with the front brake hose from the Hydraulic Control Unit (HCU) to front calliper’s twisted 180° which restricts its flexibility. This may cause it to rub and damage the outer layers of the brake hose potentially leading to brake fluid leakage and possible loss of brake pressure.

Fix: Check and if necessary replace the front brake hose.

7 vehicles · built 4 Sep 2023 to 29 May 2025

Affected motorcycles may have been produced with the front brake hose from the Hydraulic Control Unit (HCU) to front calliper’s twisted 180° which restricts its flexibility. This may cause it to rub and damage the outer layers of the brake hose potentially leading to brake fluid leakage and possible loss of brake pressure.

Fix: Check and if necessary replace the front brake hose.

12 vehicles · built 4 Sep 2023 to 29 May 2025

Affected motorcycles may have been produced with the front brake hose from the Hydraulic Control Unit (HCU) to front calliper’s twisted 180° which restricts its flexibility. This may cause it to rub and damage the outer layers of the brake hose potentially leading to brake fluid leakage and possible loss of brake pressure.

Fix: Check and if necessary replace the front brake hose.

9 vehicles · built 4 Sep 2023 to 29 Aug 2025

The rear brake disc retention bolts on specific motorcycles were insufficiently torqued.

Fix: Re-torque the rear brake disc retention bolts or replace them where necessary.

54 vehicles · built 10 Apr 2019 to 19 Dec 2019

The front brake caliper mounting bolts are not of the correct grade. If left the bolt/s could fracture and cause the front wheel to stop suddenly.

Fix: Recall the vehicles that are likely to be affected and replace the front caliper bolts with ones of the correct grade.

11 vehicles · built 28 Feb 2011 to 8 Mar 2012

The front brake caliper mounting bolts are not of the correct grade. If left the bolt/s could fracture and cause the front wheel to stop suddenly.

Fix: Recall the vehicles that are likely to be affected and replace the front caliper bolts with ones of the correct grade.

11 vehicles · built 28 Feb 2011 to 8 Mar 2012

It has been identified that the mounting bolt for the front brake caliper is not of the correct grade. If the bolt is subjected to environmental corrosion which could cause a stress corrosion fracture. This could result in the caliper becoming loose and interfering with the rotation of the wheel which could lead to loss of control of the machine.

Fix: Recall all affected machines and replace the front brake caliper mounting bolts with the correct grade of bolt.

5 vehicles · built 7 Mar 2011 to 27 Feb 2012

These motorcycles have a motor encoder position signal that may drift over the extended use of the motorcycle. Should the encoder signal drift too far it could fall beyond the signal limits expected by the motor controller. This condition could cause the motor controller to shut off resulting in the inadvertent loss of power of the motorcycle.

Fix: Recall the machines that are likely to be affected to reprogram the motorcycles motor controller with new firmware and configuration which compensate for the possible drift of the motor encoder position signal to ensure it remains within the limits expected by the controller.

11 vehicles · built 19 Dec 2011 to 23 Jul 2012

These motorcycles have a motor encoder position signal that may drift over the extended use of the motorcycle. Should the encoder signal drift too far it could fall beyond the signal limits expected by the motor controller. This condition could cause the motor controller to shut off resulting in the inadvertent loss of power of the motorcycle.

Fix: Recall the machines that are likely to be affected to reprogram the motorcycles motor controller with new firmware and configuration which compensate for the possible drift of the motor encoder position signal to ensure it remains within the limits expected by the controller.

11 vehicles · built 19 Dec 2011 to 23 Jul 2012

The brake lever travel range specification has been deemed to be too broad to ensure that the switch actuation point and corresponding brake-light activation will occur prior to moderate front brake application. This condition could lead to the brake-light not activating when moderate front braking is applied. Failure of the brake-light to activate when slowing down the motorcycle using moderate front braking may cause a hazard to drivers behind the motorcycle. This could lead to a possible crash and potential injury or death of the rider.

Fix: Replacement of the front brake system brake-light switch with a switch manufactured to a revised actuation range that ensures brake-light activation prior to moderate front braking action.

98 vehicles · built 1 Mar 2011 to 31 Mar 2012

The brake lever travel range specification has been deemed to be too broad to ensure that the switch actuation point and corresponding brake-light activation will occur prior to moderate front brake application. This condition could lead to the brake-light not activating when moderate front braking is applied. Failure of the brake-light to activate when slowing down the motorcycle using moderate front braking may cause a hazard to drivers behind the motorcycle. This could lead to a possible crash and potential injury or death of the rider.

Fix: Replacement of the front brake system brake-light switch with a switch manufactured to a revised actuation range that ensures brake-light activation prior to moderate front braking action.

98 vehicles · built 1 Mar 2011 to 31 Mar 2012

These motorcycles have a Battery Management System (BMS) printed circuit board (PCB) with insufficient weatherproofing compound on its connector pins. This condition could cause adjacent pairs of the BMS PCB connector pins to short-circuit when subjected to wet conditions. Short-circuiting of the BMS PCB connector pins could cause the motorcycle to inadvertently lose power which could lead to a possible crash and potential injury or death of the rider.

Fix: Affected machines will be recalled to be thoroughly cleaned and have weatherproofing compound applied to the BMS PCB connector pins.

143 vehicles · built 1 Dec 2011 to 30 Apr 2012

These motorcycles have a Battery Management System (BMS) printed circuit board (PCB) with insufficient weatherproofing compound on its connector pins. This condition could cause adjacent pairs of the BMS PCB connector pins to short-circuit when subjected to wet conditions. Short-circuiting of the BMS PCB connector pins could cause the motorcycle to inadvertently lose power which could lead to a possible crash and potential injury or death of the rider.

Fix: Affected machines will be recalled to be thoroughly cleaned and have weatherproofing compound applied to the BMS PCB connector pins.

143 vehicles · built 1 Dec 2011 to 30 Apr 2012

These motorcycles have a Battery Management System (BMS) printed circuit board (PCB) with insufficient weatherproofing compound on its connector pins. This condition could cause adjacent pairs of the BMS PCB connector pins to short-circuit when subjected to wet conditions. Short-circuiting of the BMS PCB connector pins could cause the motorcycle to inadvertently lose power which could lead to a possible crash and potential injury or death of the rider.

Fix: Affected machines will be recalled to be thoroughly cleaned and have weatherproofing compound applied to the BMS PCB connector pins.

143 vehicles · built 1 Dec 2011 to 30 Apr 2012

These motorcycles have a Battery Management System (BMS) printed circuit board (PCB) with insufficient weatherproofing compound on its connector pins. This condition could cause adjacent pairs of the BMS PCB connector pins to short-circuit when subjected to wet conditions. Short-circuiting of the BMS PCB connector pins could cause the motorcycle to inadvertently lose power which could lead to a possible crash and potential injury or death of the rider.

Fix: Affected machines will be recalled to be thoroughly cleaned and have weatherproofing compound applied to the BMS PCB connector pins.

143 vehicles · built 1 Dec 2011 to 30 Apr 2012

The brake lever travel range specification has been deemed to be too broad to ensure that the switch actuation point and corresponding brake-light activation will occur prior to moderate front brake application. This condition could lead to the brake-light not activating when moderate front braking is applied. Failure of the brake-light to activate when slowing down the motorcycle using moderate front braking may cause a hazard to drivers behind the motorcycle. This could lead to a possible crash and potential injury or death of the rider.

Fix: Replacement of the front brake system brake-light switch with a switch manufactured to a revised actuation range that ensures brake-light activation prior to moderate front braking action.

98 vehicles · built 1 Mar 2012 to 31 Mar 2012

The brake lever travel range specification has been deemed to be too broad to ensure that the switch actuation point and corresponding brake-light activation will occur prior to moderate front brake application. This condition could lead to the brake-light not activating when moderate front braking is applied. Failure of the brake-light to activate when slowing down the motorcycle using moderate front braking may cause a hazard to drivers behind the motorcycle. This could lead to a possible crash and potential injury or death of the rider.

Fix: Replacement of the front brake system brake-light switch with a switch manufactured to a revised actuation range that ensures brake-light activation prior to moderate front braking action.

98 vehicles · built 1 Mar 2011 to 31 Mar 2012

The brake lever travel range specification has been deemed to be too broad to ensure that the switch actuation point and corresponding brake-light activation will occur prior to moderate front brake application. This condition could lead to the brake-light not activating when moderate front braking is applied. Failure of the brake-light to activate when slowing down the motorcycle using moderate front braking may cause a hazard to drivers behind the motorcycle. This could lead to a possible crash and potential injury or death of the rider.

Fix: Replacement of the front brake system brake-light switch with a switch manufactured to a revised actuation range that ensures brake-light activation prior to moderate front braking action.

98 vehicles · built 1 Mar 2012 to 31 Mar 2012