Recall: 2009-2010 Zero DS & Zero S

05/19/2011 @ 10:13 am, by Jensen Beeler8 COMMENTS

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 Motorcycle dealers will replace the front brake caliper bracket with a redesigned component, and replace the front brake pads in case the existing pads experienced abnormal wear. The front brake fluid will also be inspected and, if signs of overheating are noted, it will be replaced and the system will be flushed. This service will be performed free of charge. This safety recall is expected to begin this month. Concerned owners may contact Zero Motorcycles at 1-888-786-9376 ext. 45, and as always the NHTSA is available at 1-888-327-4236 and

Source: NHTSA

  • “owners may experience permanent deformation when subjected to high braking loads,”

    Sometimes it’s better to just stick with the language straight from the NHTSA document. Shades of “The Elephant Man” in your version. :D

  • Having no brakes could lead to deformations?…no you’re right, I flubbed it.

  • BikePilot

    Man I hate when I get permanently deformed!

  • Oh please don’t fix it. (This comment is directed at Jensen and his writing, not at Zero and their brakes)

  • haha zero

    Well, well, well – only recalling 160, but little do they know, that accounts for the entire sales volume of the 2009 / 2010 Zero motorcycle family!

    Zero is averaging 1 recall a year – losers!

  • @haha – I was wondering when we’d hear from the douche-contingent. Why the hate for an American company that’s trying to innovate?

  • Classic.Another Fail from Zero. This Front brake set up was poorly designed from the get go.
    They knew it was problems and rolled with it anyway. Adds to their 65% failure rate.

  • Zerofan

    The real problems Zero does have is communication. I have rarely met a company that was so reluctant to take advantage or their customers and dealers to support them. They just do not want to listen. Even simple problems that are easy to fix take months. Not surprisingly customer had to ask Zero whether their bike might be affected by the problem. As Zero is selling directly to the customers in low volumes and has all the necessary data it shouldn’t take them more than three hours to call them.