Zero Motorcycles is recalling certain 2024 and 2025 DS, DSR, DSRP, and DSR/X motorcycles due to a twisted brake hose issue. On some units the front brake hose may have been twisted approximately 180 degrees, which could cause additional friction and wear that may result in a brake fluid leak and potential loss of front brake pressure. This could, in turn, increase the risk of loss of control of the motorcycle, injury, and/or a crash.
According to Zero's records, approximately 118 motorcycles across all models sold in the US may be affected. This represents approximately 30% of the population. The cause has been traced back to a manufacturing line assembly issue, where the assembly was essentially correct except the brake hose may have been twisted going to the ABS hydraulic control unit (HCU).
The problem chronology notes that this issue was first reported in December 2024, on two units. Since only two were involved, it did not immediately take action. However, additional claims were received in June 2025, at which time Zero began its investigation of the issue in earnest. The company notes that it is aware of a single instance in Europe where a rider lost control of the motorcycle due to this issue; however, it also adds that no injuries were reported.
