Campaign 25V-834

Motor controller may have been built with incorrect fasteners, causing higher resistance at the busbar joint and a loss of drive power

Defect summary

Zero Motorcycles Inc. (Zero) is recalling certain 2023 DSR/X motorcycles. The motor controller may have been built with incorrect fasteners, causing higher resistance at the busbar joint and a loss of drive power.

Consequence

A loss of drive power increases the risk of a crash.

Remedy

Dealers will replace the controller, free of charge. Owner notification letters were mailed January 19, 2026. Owners may contact Zero customer service at 1-888-841-8085. Zero's number for this recall is SV-RCL-025-021. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning December 19, 2025.

Source: NHTSA ODI recalls file, campaign 25V834000. Text as published by NHTSA.

Vehicles covered

One product line is covered

Owner complaints filed with NHTSA about electrical system on these vehicles: 0, of which 0 involved a crash, fire, injury or death. Complaints are not verified by NHTSA.

Vehicles covered by campaign 25V-834
Make	Model	Model years	Complaints on this component
Zero	Dsr/x	2023	0

Source: NHTSA ODI recalls and complaints files. Equipment, tire and child-seat campaigns list products, not vehicles.

Investigation

No NHTSA investigation is linked to this recall

Most recalls are started by the manufacturer. This one lists "Manufacturer" as its origin.

Before the recall

1 service bulletin on this component came first

Distinct manufacturer communications on the same component group, make, model and model year in the 24 months before the report date.

Source: NHTSA manufacturer communications file.

Service bulletins

25V-587 Sep 9, 2025
Improperly routed key switch signal wires may break, causing a loss of drive power
20V-640 Oct 15, 2020
DC-DC converter has an insufficient power output margin to operate the anti-lock braking system (ABS), instruments, lights, indicators, and any…
18V-215 Apr 4, 2018
Cell pouches in the battery packs may wear from contact with the holders, allowing humidity to enter the pouch and cause an electrical short…
16V-610 Aug 22, 2016
Affected motorcycles have a DC-DC converter that may have insufficient output power
13V-635 Dec 18, 2013
Affected motorcycles have controller firmware that, as a result of certain system faults, may shut off power to the motor
13V-257 Jun 20, 2013
Manufacturing defect with the sealant material in the battery may allow water to penetrate the battery and contact the cells