Zero Motorcycles Inc. has rolled out a recall for 2024 DS, DSR, DSR/X and DSRP. The brake line of the front brake can twist and be damaged, so that brake fluid can leak and the brake pressure can fall away.
With the assembly of the above models, the brake lines are possible for 180 ° for the caliper, which limits the designed flexibility by the “P-clamp”, which leads to friction and damage to the outer layers of the brake pipe, which can lead to leakage of the brake fluid and possibly loss of brake pressure.
In December 2024, Zero Motorcycles received two warranty claims for leaking brake lines. With one report there was loss of control due to reduced braking power, but there were no injuries. In June 2025, another eight claims were received, six of which were from Europe. In one of those cases in Europe, the rider had lost control of his zero because of the reduced braking capacity.
On July 8, 2025, the Integrity Team product met Zero Motorcycles to assess the information collected about the twisted brake pipe, which caused the reduced flexibility. It was determined that a distortation of 180 ° was in the braking line for the main cause on which the research team advised the company to voluntarily roll out a recall.
The Zero Motorcycles dealers will inspect the distortion and any damage to the management as a result of the distortion. If the pipe is turned or if it is damaged, the dealer will replace the pipe and mount it correctly.
Dealers then submit a warranty claim for the parts and labor for the repair/replacement. The working time for inspection is 30 minutes and replacement is 1 hour and 30 minutes. Zero Motorcycles has not developed a separate reimbursement plan for this recall because all motorcycles are under warranty and no owner would have to pay this repair from his own pocket.
– Thanks for information from Motorfreaks.