Zero Motorcycles Inc. has issued a safety recall affecting 118 electric motorcycles from the 2024-2025 model years. NHTSA Campaign Number 26V048 addresses a manufacturing defect where the front brake hose may have been installed with a 180-degree twist, potentially leading to brake fluid leakage and loss of brake pressure.
Highlights
- 118 motorcycles affected: 2024-2025 Zero DS, DSR, DSRP, and DSR/X models produced between March 19, 2024, and May 29, 2025
- Root cause: Front brake hose twisted during installation, restricting flexibility and causing hose damage through contact with the p-clamp
- Safety risk: Brake fluid leakage can result in reduced braking capability and loss of vehicle control
- Remedy: Dealers will inspect and replace brake hoses as necessary at no charge to owners
Defect Description
The affected motorcycles may have been assembled with the front brake hose connecting the Hydraulic Control Unit (HCU) to the calipers twisted 180 degrees. This incorrect orientation restricts the designed flexibility of the hose through the p-clamp mounting point.
The restricted movement causes the hose to rub against components, damaging the outer layers. Over time, this damage can lead to brake fluid leakage and a corresponding loss of brake pressure in the front braking system.
Affected Vehicles
The recall covers multiple Zero Motorcycles models across two model years:
- 2024 Zero DS: 14 units
- 2025 Zero DS: 25 units
- 2024 Zero DSR: 15 units
- 2025 Zero DSR: 9 units
- 2024 Zero DSRP: 24 units
- 2025 Zero DSRP: 7 units
- 2024 Zero DSR/X: 1 unit
- 2025 Zero DSR/X: 23 units
All affected vehicles were produced between March 19, 2024, and May 29, 2025. Zero estimates that approximately 30 percent of the 118 potentially involved motorcycles may exhibit the defect.
Investigation Timeline
Zero Motorcycles received initial warranty claims in December 2024 reporting leaking brake hoses. One claim documented a loss of control event due to reduced front braking, though no injuries occurred. The low volume of reports prompted monitoring rather than immediate action.
In June 2025, eight additional claims surfaced, including six from a European fleet. Investigation determined that a 180-degree twist in the front brake hose was the root cause of the failures.
The Product Integrity Team met on July 8, 2025, to review findings. Based on this review, the team recommended a voluntary safety recall for inspection and replacement of affected brake hoses.
Recall Expansion
On January 15, 2026, Zero received reports of two additional vehicles outside the originally determined VIN range exhibiting the same defect. This discovery prompted expansion of the recall scope to include all vehicles manufactured prior to a production line correction.
Zero is aware of one incident in Europe where a rider lost control due to reduced braking capability. No injuries were reported in connection with this recall.
Production Correction
Zero Motorcycles implemented a corrective measure on July 28, 2025. A mechanical poka-yoke jig was introduced to the production line that physically prevents installation of the brake hose in an incorrect orientation. Vehicles produced after this date are not subject to the recall.
Remedy Program
Authorized Zero Motorcycles dealers will perform the following:
- Inspection: Examine brake hose for twist condition and any resulting damage (0.50 hours labor)
- Replacement: If twist or damage is present, replace hose and route correctly during installation (1.50 hours labor)
All repairs will be performed free of charge. Zero has not developed a separate reimbursement plan because all affected motorcycles remain under warranty coverage.
Owner Notification Schedule
Zero Motorcycles has established the following notification timeline:
- Dealer notification: February 4-6, 2026
- Owner notification letters: February 23-27, 2026
- VIN searchable on NHTSA.gov: February 27, 2026
Owners may contact Zero customer service at 1-888-841-8085. The manufacturer’s internal recall number is SV-RCL-025-017.2.
Subscribe Today!
Sign up for our weekly eNewsletter and get a free copy of our quarterly digital magazine.
