Recall: 2014 Zero Motorcycles S, SR, DS, & FX

04/07/2014 @ 4:09 pm, by Bryan Delohery6 COMMENTS


As you may remember from our previous coverage, things are not looking so good for Zero Motorcycles with several recalls in the past year, including  faulty brake caliper mounting bolts that was issued in August, and a faulty firmware recall that caused certain models to shut down while running.

Now, after an incident with an expert rider in Australia in late February, Zero has discovered that when certain motors are pushed to their limits, the motors rotor may contact the stator, causing the engine to lock up thereby causing the rear wheel to lock up.

According to the Zero Motorcycles incident report, the mishap in Australia did not result in injury or an accident, though it became apparent that this condition was most likely to occur during sustained maximum rpm.

Zero was able to reproduce the failure on an engine dyno when a factory motor was tested at sustained maximum rpm and temperature.

As of March 10, neither Zero nor the manufacturer of the motors were able to determine what the root cause of the motor lockup was, but after their investigation concluded that certain models built before February 24th, 2014 could be affected.

As part of the remedy, Zero will be performing a stationary screening test of the motors while they are still in the motorcycle, and replacing faulty units with pre-screened ones at no cost to the owner

Although Zero is not aware of any accidents or injuries to date, they are advising dealers and owners who continue to ride their motorcycles before being screened to keep the rpm’s below 5,000.

Affected units include:

  • 2014 model year Zero SR model motorcycles built 12/30, 2013 through 02/20, 2014
  • 2014 model year Zero S model motorcycles built 12/26, 2013 through 02/ 18, 2014
  • 2014 model year Zero DS model motorcycles built 01/24, 2014 through 02/04, 2014
  • 2014 model year Zero FX model motorcycles built 01/14, 2014 through 01/27, 2014

If you own one of the following models, the recall is expected to being sometime in April and you may contact Zero at 1-888-786-9316 (1-888-RUN-ZERO), or the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153) or go to

Source: NHTSA

  • paulus

    “As part of the remedy, Zero will be performing a stationary screening test of the motors while they are still in the motorcycle, and replacing faulty units with pre-screened ones at no cost to the owner”

    The manufacturer spin always annoys me (not only Zero but all manufacturers). It is made to sound like they are doing the consumer a favour.

    For sure it should be free… it is a design/manufacture issue. The manufacturer is fully liable. Especially for a potential safety issue. They should be actually doing more than ‘free replacement’ only. . Free service for a period, or at least something. There is risk, time and inconvenience to the owners as a result of this type of issue.

  • paulus, I agree with you.

    The same thing happen in Malaysia for Kawasaki bike from ER6N, ER6F and Versys model, there are a lot of thing has been done by Kawa rider in Malaysia to push Kawasaki to make a recall & they got it at last but still they have to bear 30% repair cost due to engine breakdown.

    Google translate :

    Hot discussion (in Malay) :

  • I guess the government is good for something. I remember when there was no such thing as a recall. A warranty yes. Really how does anyone expect something as complicated as modern consumer goods to have no fault in design or construction for an indefinitely long time in varied use and abuse? Soon we can buy something and will go to the moon. Yes manufacturers are doing us a huge service. I wish my ’56 Matchless had recalls! What a joke, they would be spending all their time fixing maybe 100 bikes, over and over again. It was fun to ride though(while it ran) and looked and sounded bitchen!

  • Know Nothing

    I, for one, am excited for Paulus’ new motorcycle marque! Best of success!

  • Bluey

    so far, they build crap motorcycles. honestly.

  • Westward

    I give credit to Zero for stepping and accepting responsibility. Unlike GM, who knew their faults, did research, a cost analysis, then decided a recall was too costly. Even after 13 people died and at least 33 people known to be injured.

    See, that’s why I would never buy an American made car from GM, Ford, or Chrysler. Because they have a history of negligence that have proved fatal.

    Zero on the other hand, seems to have moved ahead and attacked the problem before someone gets seriously hurt. Makes a consumer feel a little more respected for the hard earned money one spends.

    Bravo to Zero for accountability, they have shown their quality, in an age where many others have been greatly lacking…