Zero Motorcycles is recalling certain Adventure Touring models from their DS line (DSR/X, DS, DSR, and DSRP) due to potential power loss issues that can occur while the bike is being operated. It is estimated that a total of 319 bikes from model years 2023-2024 are affected by the recall filed with the National Highway Traffic Safety Administration (NHTSA).

According to the safety report, improperly routed key switch wires may become damaged and break, causing a sudden loss of forward propulsion. While the motorcycles were built according to the existing design standard, the original wire routing plan has proven to be vulnerable to wire fatigue over time. The failure occurs when the key switch wires break as a result of one of two conditions:

• 1.) Connector contact with the headtube – In certain harness routing configurations, the key switch connector is positioned too close to the headtube. Normal steering motion and vibration can cause the connector or attached wires to flex or press against the frame, leading to wire fatigue and eventual breakage.

• 2.) Over-constrained harness at zip tie – In some cases, the harness is secured too tightly with a zip tie, creating a pinch point that places excessive stress on the key switch wires. This mechanical strain can cause internal wire fatigue and breakage over time, particularly under vibration or steering movement.

So far only a low number of field cases have been reported involving damage to the key switch signal wires, with an estimated 0.6% of models being affected. Although the overall failure rate is low, the nature of the failure poses a serious safety risk.

After reviewing the claim history and determining the root cause, the Zero Motorcycles Product Integrity team recommended a voluntary safety recall. So far Zero Motorcycles is aware of one incident involving a dropped motorcycle, with no injuries reported.

Models Affected By The Recall

In either of the two failure scenarios, damaged wiring may result in the loss of the key switch signal to the motor. Under current system behavior, this signal loss causes an immediate shutdown of propulsion, even if the vehicle is in motion. While this system response is consistent with the existing design, it may increase the risk of a crash, injury or death if the rider is unable to safely maneuver or bring the motorcycle to a controlled stop.

A complete power loss is not always the case though. Some riders have reported intermittent symptoms prior to the failure, such as a brief loss of power. But not all incidents are preceded by warning signs. In several cases the vehicle shut off abruptly without any prior indication of a problem.

How To Get It Fixed

The remedy consists of a firmware update that prevents sudden power loss by detecting key switch signal interruption and initiating a controlled transition into limited-power (“limp”) mode. If the signal is lost, a warning will appear on the dash, and the motorcycle will remain fully operational. After decelerating to 40 kph, the system will transition into limp mode.  The vehicle will remain in this state until it comes to a complete stop and the key is turned off.

In addition to the firmware update, updating the wire harness routing and zip tie orientation will reduce mechanical stress on the ignition switch wires. The firmware can be updated by a dealer, or by the owner through an over-the-air (OTA) update, while the wiring harness fix will need to be completed at a dealer. Both remedies can be completed at a Zero Motorcycles dealer free of charge.

Owner notification letters are expected to be mailed by September 29, 2025. If you think your bike might be affected you can contact Zero customer service at 1-888-841-8085 to request information about manufacturer recall number SV-RCL-025-018. You may also contact the NHTSA Hotline at 1-888-327-4236 or check if your bike is involved in the recall by entering its VIN number at www.nhtsa.gov.