Zero Motorcycles has rolled out a voluntary recall for the 2023-2024 DSR/X and the 2024 DS, DSR and DSRP. Cause: incorrectly placed cables of the ignition lock that can break through tension and vibrations, as a result of which the engine drops out without warning while driving.
From first complaints to recall
The first reports arrived in 2023, when Zero traced a starting problem to the wiring of the ignition lock. Four new cases followed in 2024, and this year another five were added – including one incident in which a rider fell over at low speed after the engine suddenly dropped out. Fortunately, injuries were not fallen.
Research showed that the cables could die for two reasons:
– Connector against the head – steering movements and vibrations cause wire break.
– Tie-wraps too tightly fixed cable tree put too much tension on the wiring.
Because such a fracture immediately removes the ignition lock signal, the engine will immediately switch off in the current software-also while driving.
The solution
Zero is now releasing a firmware update that takes away this risk. With signal loss, a warning appears on the dashboard from now on, after which the engine will continue to drive. Only after braking up to 40 km/h does the system automatically switch to a limp mode with limited power. The engine remains active in that position until you are completely stationary and turn off the contact.
In addition, the cable harness and tie-wraps are adjusted, so that less mechanical voltage will be placed on the wiring.
All necessary repairs are carried out free of charge, and those who have previously had this problem fixed out of their own pocket will be reimbursed for the costs by Zero.
👉 Are you driving a Zero DSR/X or DS/DSR/DSRP from year 2023–2024? Then contact your dealer to check whether your motorcycle falls under this recall.
– Thanks for information from Motorfreaks.