Zero S recalls by model year

Reported: 2011-05-16 (May 16, 2011) · Model years: 2009, 2010

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.

Consequence: 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.

Remedy: DEALERS WILL REPLACE THE FRONT BRAKE CALIPER BRACKET WITH A RE-DESIGNED COMPONENT, AND REPLACE THE FRONT BRAKE PADS IN CASE THE EXISTING PADS EXPERIENCED ABNORMAL WEAR. THE FRONT BRAKE FLUID WILL ALSO BE INSPECTED AND, IF SIGNS OF OVERHEATING ARE NOTED, IT WILL BE REPLACED AND THE SYSTEM WILL BE FLUSHED. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 31, 2011. OWNERS MAY CONTACT ZERO MOTORCYCLES AT 1-888-786-9376 EXT 45.

Reported: 2012-06-29 (June 29, 2012) · Model years: 2011

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.

Consequence: 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.

Remedy: ZERO WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE FRONT BRAKE SYSTEM BRAKE-LIGHT SWITCH FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 3, 2012. OWNERS MAY CONTACT ZERO MOTORCYCLES AT 1-831-438-3500.

Reported: 2013-07-30 (July 30, 2013) · Model years: 2011

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.

Consequence: 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.

Remedy: Zero Motorcycles will notify owners, and dealers will replace the front caliper bolts. The recall BEGAN ON August 16, 2013. Owners may contact Zero Motorcycles at 1-888-841-8085.

Reported: 2013-12-18 (December 18, 2013) · Model years: 2013

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.

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

Remedy: Zero will notify owners, and dealers will update the controller firmware, free of charge. The recall is expected to begin in mid-January 2014. Owners may contact Zero at 1-888-786-9376.

Reported: 2014-03-12 (March 12, 2014) · Model years: 2014

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.

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

Remedy: Zero will notify owners, and dealers will test the motor and if it fails testing, replace it, free of charge. The recall began in April 11, 2014. Owners may contact Zero at 1-888-786-9316 (1-888-RUN-ZERO).

Reported: 2016-08-22 (August 22, 2016) · Model years: 2015

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.

Consequence: 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.

Remedy: Zero has notified owners, and dealers will inspect the DC-DC converters, replacing ones of a specific type as necessary, free of charge. The recall began on September 16, 2016. Owners may contact Zero customer service at 1-888-841-8085. Zero's number for this recall is SV-ZMC-016-356.

Reported: 2017-03-07 (March 7, 2017) · Model years: 2017

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.

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

Remedy: Zero will notify owners and dealers will reconfigure the HCU, or replace it as needed, free of charge. The recall began on March 13, 2017. Owners may contact Zero customer service at 1-888-841-8085. Zero's number for the recall is SV-ZMC-017-363.

Reported: 2017-07-10 (July 10, 2017) · Model years: 2017

Zero Motorcycles Inc. (Zero) is recalling certain 2017 S ZF6.5, S ZF13.0, DSP ZF13.0, and SR ZF13.0 motorcycles. In the event that a turn signal stops working, the turn signal flasher may not change its flash rate to alert the operator. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, "Lamps, Reflective Devices, and Associated Equipment."

Consequence: If motorcycle is operated without knowing that a turn signal is not working, there would be an increased risk of a crash.

Remedy: Zero will notify owners and dealers will test the motorcycle's flasher, replacing it as necessary, free of charge. The recall began on July 25, 2017. Owners may contact Zero customer service at 1-888-841-8085. Zero's number for the recall is SV-ZMC-017-369.

Reported: 2017-11-28 (November 28, 2017) · Model years: 2018

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."

Consequence: 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.

Remedy: Zero will notify owners, and dealers will replace the incorrect label with a corrected label, free of charge. The recall is expected to begin in December 2017. Owners may contact Zero customer service at 1-888-841-8085. Zero's number for this recall is SV-ZMC-017-380.

Reported: 2020-10-15 (October 15, 2020) · Model years: 2021

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.

Consequence: 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.

Remedy: Zero will notify owners, and dealers will replace the DC-DC converter, free of charge. The recall began October 26, 2020. Owners may contact Zero customer service at 1-888-841-8085. Zero's number for this recall is SV-ZMC-021-019.