Brake Hose Defect Prompts Recall of Zero Motorcycles Due to Safety Concerns

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Owners of select 2024 Zero electric motorcycles should prepare for safety inspections and potential repairs following a recent recall impacting four popular models. The manufacturer, Zero Motorcycles Inc., has identified a defect in the front brake hose routing that could significantly reduce braking performance, increasing the risk of accidents.

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The recall affects 44 units of the 2024 Zero DS, DSR, DSRP, and DSR/X motorcycles manufactured between September 4, 2023, and February 23, 2024. Approximately 30 percent of those units are estimated to have the defect. According to the recall notice submitted to the National Highway Traffic Safety Administration (NHTSA), the defect stems from a 180-degree twist in the front brake hose, which may restrict movement, cause abrasion, and ultimately lead to brake fluid leakage and a loss of brake pressure.

Motorcycle owners are advised not to ride their affected vehicles and to park them outdoors until inspected. Loss of front brake function can reduce control and heighten the risk of a crash, although no injuries have been reported to date. One incident in Europe did involve a rider losing control due to diminished braking capability.

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Zero Motorcycles dealers will inspect the front brake hose for signs of twisting or wear. If damage is found, the hose will be replaced and correctly routed. All affected motorcycles are under warranty, so owners should not expect to incur any out-of-pocket expenses. Notifications to dealers are scheduled to begin the week of July 21, 2025, and owners will begin receiving official recall notices by the week of July 28, 2025. Affected vehicle identification numbers (VINs) will also be searchable on that date.

This recall underscores the importance of routine safety inspections, especially for newer models. Zero Motorcycles took action after receiving multiple warranty claims and determining that the manufacturing process may have introduced the issue during installation of the ABS hardware.

Article by multiple contributors, based upon information from a National Highway Traffic Safety Administration press release.

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