Do you own a 2023 Zero DSR/X motorcycle? If you do, then you need to know about a new recall that Zero Motorcycles has initiated for all 2023 DSR/X units sold in the US. Due to fasteners being used in the assembly of the motor controller that are not the usual, phosphate-coated ones, an overvoltage potential exists that would not exist if the usual fasteners had been used. These fasteners were used due to a shortage in materials at the time of manufacturing.
This is a long and roundabout way of saying that motorcycles with the affected motor controllers installed could very suddenly lose propulsion in operation. This could increase the risk of an injury or crash, and Zero advises that there is no warning sign that may occur prior to this situation occurring.
According to Zero's records, approximately 7 total DSR/X are believed to be affected. These bikes were manufactured between July 4, 2022 and April 21, 2023, and represent 100% of the population. Zero's event chronology noted reports of issues arising in September 2025 of "quits while running" cases in which neither injuries nor crashes were reported. Nevertheless, "quits while running" is not something any motorcycle manufacturer (or owner, for that matter) wants to see.
Please note that this recall only affects motorcycles produced within the specified time range. Zero notes that the condition was corrected in production once the parts shortage had resolved, so motorcycles produced outside this range should not be affected.
Zero Motorcycles is notifying its dealer network about this recall between December 5, 2025 and December 19, 2025. Additionally, the company plans to notify registered owners between January 9, 2026 and January 16, 2026.
Owners will be instructed to schedule a recall service with their local authorized Zero Motorcycles dealer. The service will involve technicians replacing the motor controller unit on the affected motorcycles, at no cost to the customer.
Owners may contact Zero Motorcycles customer service at 1-888-841-8085 regarding recall number SV-RCL-025-021. Owners may also contact the US National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-888-275-9171) or go to www.nhtsa.gov.
