2012 Zero Zero Ds

The 2012 Zero DS has 3 recalls, all rated at the same severity level, covering fire risk from battery pack wear, sudden front wheel lockup from corroding brake caliper bolts, and unexpected power loss while riding.

The battery recall involves cell pouches inside the battery pack that can wear where they contact their holders, allowing moisture to enter and cause an electrical short that raises the risk of fire. On the braking side, the front brake caliper mounting bolts can corrode, crack, and fracture over time. If a bolt breaks, the caliper can come loose and catch on the spinning front wheel, bringing it to a sudden stop and throwing the rider. There is also an electrical issue with the motor encoder, a sensor that tracks the motor's position to keep it running properly. On some bikes, this signal can drift out of range after extended use, causing the motor controller to shut off and cut power without warning while the motorcycle is in motion.