Zero Motorcycles has announced a new safety recall affecting several 2024–2025 DS‑series models after identifying an issue with the routing of the front brake hose that could lead to brake‑fluid leakage and reduced braking performance. The recall covers 118 motorcycles built between March 19, 2024 and May 29, 2025.

According to the recall report, some units may have been assembled with the front brake hose twisted 180 degrees from the hydraulic control unit to the calipers. This incorrect orientation limits the hose’s ability to flex naturally through the P‑clamp, causing it to rub and wear through its outer layers. Over time, the abrasion can progress to the point of fluid leakage, which may compromise front‑brake performance and increase the risk of a crash. Riders might notice visible wear, fraying, or signs of fluid seepage, or they may experience braking behavior that feels inconsistent with normal operation.

The affected lineup includes the 2024–2025 Zero DS, DSR, DSRP, and DSR/X. Zero expanded the recall population after determining that additional units built before the introduction of a new assembly jig could also exhibit the defect. A mechanical poke-a-yoke jig added on July 28, 2025 now prevents incorrect hose orientation in production, and motorcycles built after that date are not included in the campaign.

Models Affected

To remedy the issue, Zero dealers will inspect the front brake hose for twisting or damage. If the hose shows no signs of wear, technicians will re‑route it correctly to restore proper clearance and flexibility. If abrasion or leakage is present, the hose will be replaced and installed with the correct routing. Zero estimates the inspection will take about half an hour, while replacement requires roughly an hour and a half. All work will be performed free of charge, and the company notes that no reimbursement program is necessary because all affected motorcycles remain under warranty.

Zero plans to notify its dealer network during the week of February 2, 2026, with owner notifications scheduled for February 23–27, 2026. Owners may contact Zero customer service at 1‑888‑841‑8085, and the company has assigned SV‑RCL‑025‑017.2 as its internal reference number for this campaign. Vehicle Identification Numbers included in the recall will become searchable on NHTSA.gov beginning February 27, 2026, with the federal listing filed under NHTSA Recall No. 26V‑048.