Summary
The Zero S has 11 recalls spanning 2009 through 2018, with the most serious being a 2014 model year defect where the electric motor's rotor can contact the stator, causing the motor to seize and the rear wheel to lock up suddenly.
The 2017 model year has two ABS-related issues: the anti-lock braking system's hydraulic control unit may contain incorrect vehicle model information or incorrect software, either of which can cause the ABS to behave improperly during hard braking and extend stopping distances. There is also a 2017 turn signal flasher that fails to change its flash rate when a bulb burns out, leaving the rider unaware that a turn signal is not working.
The 2018 model year has a compliance issue where the emissions label displays the wrong model year, which could cause confusion if a recall notice is ever issued for those motorcycles.
Going back to 2012, two separate electrical issues affect that model year: battery cell pouches can wear against their holders, breach their outer layers, and allow moisture inside the pack, and the motor controller can shut off unexpectedly, cutting power while the motorcycle is in motion.
The 2011 model year has a front brake caliper mounting bolt that can break, causing the caliper to interfere with the front wheel and lock it up without warning. A separate 2011 issue involves a brake light switch that does not activate until the rider has pulled the front brake lever a significant distance, meaning the brake light may not illuminate during moderate braking and trailing traffic may not realize the motorcycle is slowing.
On 2009 and 2010 models, the front brake caliper bracket can deform under hard braking, allowing the brake pads to misalign with the rotor and reducing front braking effectiveness.
