3 recalls across 2 model years
The Zero DS has 3 recalls covering the 2011-2012 model years, with the most serious being a 2012 battery pack defect where cell pouches wear against their holders, allowing moisture inside and creating an electrical short that can lead to a fire.
The 2012 model year also has a motor encoder that can drift out of calibration over time, causing the motor controller to cut power without warning while riding. On 2011-2012 models, the front brake caliper mounting bolts are susceptible to corrosion that can cause them to crack and fracture. If a bolt breaks, the caliper can work loose and lock the front wheel, bringing the motorcycle to a sudden stop.
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