Well...she's back!
The dealer in Houston called me a couple days after I dropped it off and told me that they had contacted Zero and a new fork was on its way. This was the same brand-new fork that had been installed less than two months prior. Not sure if Zero agreed to send a fork straight away due to awareness of my ongoing fork issues, or because the problem was unrepairable. I didn't care as long as it was finally fixed.
A little over a week later, the dealer called again. The new fork had arrived, but it was not the right one for my bike, and further, it had been damaged in shipment. Zero shipped a second fork. Unfortunately, it came regular freight, so it took another 7 or 8 days. But I'm only riding on weekends now, so no great loss (and now at least, I can pick the bike up on the way home from work, rather than make a 400-mile round trip).
Got it back Saturday, but didn't ride until today. Put about 30 miles on it, and so far, no apparent leakage. Keeping my fingers crossed.
While all this is frustrating, I do consider myself fortunate in a way, that my problems are with the "dumb" equipment. I haven't had "glitch" or other electrical/electronic issues. It was 102F today here, and I didn't have any problems or thermal warnings, even though I left it parked out in the sun a couple times.
Glad to be riding again