Zero S Recalls

The Zero S has 13 recalls spanning 2009 through 2021, with the most serious recent issue affecting 2021 models where the DC-DC converter can shut down under high electrical load, cutting power to the anti-lock brakes, instruments, and lights simultaneously while riding.

The 2021 recall shares its core problem with a similar issue on 2015 models, where the same type of converter could fail during an ABS activation event, disabling the braking assist and all lights at once. On 2017 models, the ABS hydraulic control unit may carry incorrect vehicle information, causing the anti-lock system to behave unpredictably during hard braking. A separate 2017 issue involves the turn signal flasher failing to change its flash rate when a turn signal bulb stops working, leaving the rider unaware that other road users cannot see the signal.

Going back to 2014, a motor rotor-to-stator contact defect can cause the motor to seize and lock the rear wheel, raising the risk of a crash. The 2012 model year has two electrical concerns: battery cell pouches can wear against their holders, breach their outer layers, and allow moisture inside, and the motor controller can shut off without warning, cutting propulsion unexpectedly.

The 2011 model year has a front brake caliper mounting bolt issue where incorrect bolts can break and allow the caliper to interfere with the front wheel, causing sudden lockup. There is also a 2011 brake light switch that may not activate until the lever is pulled well past a moderate braking position, leaving following traffic unaware the rider is slowing.

The earliest production years, 2009 and 2010, have two brake-related issues: front brake pads that can sit misaligned against the rotor and reduce braking performance, and a front brake caliper bracket on 2009 models that can deform under hard braking, again causing pad misalignment and longer stopping distances.