The 2012 Zero DS has 3 recalls, with the most serious risks being fire, sudden loss of braking, and unexpected power cutout, any of which can cause a crash.
On the battery side, cell pouches inside the battery pack can wear where they contact their holders, letting moisture in and causing an internal short that raises the risk of fire. The front brake caliper mounting bolts can corrode, crack, and fracture, allowing the caliper to shift and lock the front wheel without warning. There is also an electrical issue with the motor encoder, a sensor that tracks the motor's position: its signal can drift out of range over time, causing the motor controller to cut power while the motorcycle is in motion.
At a glance
What can fail
Battery cell pouches wear from contact with holders, allowing humidity inside and creating an electrical short in the battery.
What the fix does
Zero will repurchase your motorcycle or provide financial trade assistance toward a newer Zero model. Dealers will pick up your motorcycle at no cost.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
The front brake caliper bolts can corrode, crack, and potentially break on certain 2011 and 2012 S and DS motorcycles.
What the fix does
Dealers will replace the front caliper bolts with new ones.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The motor encoder position signal may drift during extended use. If it drifts outside normal parameters, the motor controller shuts off, causing the motorcycle to lose power unexpectedly.
What the fix does
Dealers will reprogram the motor controller at no charge to correct the signal issue.
Summarized — see the official notice for exact wording, dates, and contacts.
