Zero Motorcycles has announced the full-commencement of production for its 2012 model line, which is expected to hit dealers in February & March of this year. First off the line was the 2012 Zero DS back in December, though the electric motorcycle company has recently started building the Zero S, Zero XU, Zero X, and Zero MX at its Scotts Valley facility as well. A story we broke back in November, Zero Motorcycles debuted its important 2012 electric motorcycle line up at the 2011 EICMA show in Milan, with the 2012 range being a substantial improvement upon the company’s previous offerings.

Boasting 6kWh & 9kWh battery packs, the 2012 Zeros have nearly double the available energy on board, with the styling and performance aspects of the bikes have been improved upon as well. Zero claims that the street-focused Zero S can hit up to 114 miles on that 9kWh pack (and also does a top speed of 88 mph on its new motor), making it more practical for the urban commuter. For 2012, all of Zero’s street models feature new brushless motors, and include regenerative braking, which charges the motorcycle’s batteries during deceleration.

Our first proper leak ahead of the upcoming EICMA show in Milan is now officially in the bag, as Asphalt & Rubber has gotten word on Zero Motorcycles’ 2012 electric motorcycles. Completely revamping its model range, our sources tell us that the 2012 Zero Motorcycles will have all-new motors, battery packs, and bodywork. Talking in numbers, the battery pack options will be 6kWh & 9kWh, with prices expected to be $11,000 and $13,000 respectively. Perhaps the most compelling news (and there’s plenty to be compelled about with this news) is that Zero Motorcycles plans to have the new models under production in December, and on dealer floors by January.

An article from our friends at CMG tipped us off to the fact that Zero Motorcycle has begun promoting its electric motorcycles through several Costco stores in Canada. Taking a page from Kawasaki’s playbook in working with Costco (which is itself a take on what automobile dealers have been doing with the warehouse brand for years), Zero currently has displays in six Canadian Costco warehouse stores, working as a part of the wholesaler’s Membership Benefits Program. Like the Kawasaki program, Costco isn’t actually selling Zero Motorcycles, but instead Costco members recieve a special value package if they purchase a Zero through the promotion.

If that raises your eyebrows, here is a quick primer on the Costco business model. Generally speaking, Costco keeps its company very efficient and lean by keeping very low inventories — I’ve heard it quoted that the company won’t carry more inventory than what it can sell in one to two weeks. Helping drive that turnover are the low prices that the company is known for, but instead of doing a high volume/low margin sales approach, Costco’s true bread & butter is its membership fees.

Zero Motorcycles is recalling 160 of its electric DS & S motorcycles for an issue with the front brake caliper. Because of the defect, owners may experience permanent deformation of their brake discs when subjected to high braking loads, which induce misalignment of the front brake pads with respect to the front brake rotor. Accordingly, misalignment of the brake pads in relation to the rotor may cause reduced front braking performance, which could lead to a possible crash and potential injury or death of the rider.

The pertinent models and build dates are as follows:

• 2009 Zero S – September 2, 2009 through December 22, 2009
• 2009 Zero DS – July 27, 2009 through December 28, 2009
• 2010 Zero S – February 1, 2010 through March 31, 2011
• 2010 Zero DS – January 20, 2010 through March 31, 2011

Zero Motorcycles has quietly announced some interesting news: that Mark Blackwell, V.P. of Motorcycles at Polaris Industries, will be joining the electric motorcycle company’s Board of Directors. With a plethora of reasons as to why an industry veteran like Blackwell would join Zero’s board, it’s been no secret that the Scotts Valley company has been collecting seasoned industry professionals like pokemon characters, seemingly building a brain trust of people who actually know how to run a motorcycle company.

Blackwell’s addition to Zero is interesting because it could signal a relationship with the Polaris V.P. that goes beyond merely an advisory/visionary position, which is the core responsibility of a companies board. The timing is interesting as well, as Polaris has been on a buying spree, first acquiring the original American motorcycle company brand: Indian Motorcycles, and a few days later electric car manufacturer GEM. With a Polaris executive sitting on Zero’s board almost immediately after these aquisitions, one has to wonder if this isn’t a precursor to some sort of larger arrangement between the two companies.

Unless you were there, you probably missed the AMA Mini Moto SX racing action last Friday in Las Vegas, which saw the debut of two bikes by Brammo, an electric mini moto the Brammo Encite, along with the full-sized Brammo Engage dirt bike. Featuring the company’s Integrated Electric Transmission (IET), Brammo took to the dirt to compete with some Zero electric bikes (Quantya seemingly abstained from the event), as well as a field of traditional gasoline-powered mini motos.

With footage from aboard Trevor Doniak’s Zero MX, we get to see what racing in the Vegas Mini Moto SX was like from behind the handlebars. Besides having a traffic jam of slower gas-powered bikes start ahead of them (it’s creepy how quiet the start for the electrics was in comparison), the old addage that “rubbin’ is racing” comes to mind as we see our protagonist hit the dirt, not once, not twice, but three times, seemingly always with a Brammo rider nearby.

We’re not saying that Doniak’s Zero was intentionally looking to take out the Brammo of Kris Keefer, thus assuring a podium sweep by Zero, but others are. Video after the jump.