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.
Since the manufacturing time of the affected motorcycles, Zero has introduced a poka-yoke jig (for those unfamiliar with that term, it's an old-school Japanese term that basically means "avoid mistakes) to prevent the hoses from becoming twisted during the manufacturing process.
All affected motorcycles that Zero is recalling were manufactured between March 19, 2024 and May 29, 2025. Warning signs that owners may notice include visually spotting a frayed or damaged front brake line, with or without brake fluid leaking. Additionally, the front brakes may not function as expected on affected units.
Zero Motorcycles plans to notify its dealer network about this issue between February 4 and 6, 2026. Registered owners of motorcycles affected by this recall will be notified between February 23 and 27, 2026.
Regarding recall service, owners will be instructed to contact their local authorized Zero Motorcycles dealer so that a technician can inspect the front brake hose for any signs of damage, as well as any inappropriate twisting. If either or both conditions are found, the brake hose will be replaced and correctly routed and installed, free of charge to the customer.
Owners may contact Zero Customer Service at 1-888-841-8085 regarding Zero recall number SV-RCL-025-017.2. Additionally, owners may contact the US National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-888-275-9171) or go to www.nhtsa.gov. VINs involved in this recall will be searchable on the NHTSA website after February 27, 2026.
