ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: KuRi on September 25, 2025, 01:54:34 PM
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Hi!
Another recall for Zero DS/R/X
https://zeromotorcycles.us17.list-manage.com/track/click?u=092c52059ddeb356b88e61baf&id=1d9546151f&e=1a809af787
It says that the harness may be incorrect and that they have provided a firmware update that limits the speed if a disconnect is detected.
But... why not fix the harness???
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gonna be a bit of labor on that one, pull all the fairings off, un tie all that crap, snake the old harness off, put new one on. yah fun.
also kuri it seems your link has expired.
aaron
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Link updated, thanks!
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I think they are going to fix the harness.
Currently if it acts up, the bike shuts down and coasts to a stop until you do a hard reboot ie turn off and turn on.
The software 'fix' is to not just kill it, but limp it down so you still have power / control over it, and THEN when you do cycle the key / ie reboot, it goes back to normal mode again.
Bring it to the dealer to fix is what i think they said.
Aaron
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Hi!
Another recall for Zero DS/R/X
https://zeromotorcycles.us17.list-manage.com/track/click?u=092c52059ddeb356b88e61baf&id=1d9546151f&e=1a809af787
It says that the harness may be incorrect and that they have provided a firmware update that limits the speed if a disconnect is detected.
But... why not fix the harness???
Sounds like an issue I had on my 2016 DSR in that several times the bike suddenly shut off & turned back on just as fast with no inputs/actions from me.
In my case it turned out to be a keyed (On/Off) switch wire pinched by the headstock.
The update looks to be a means of lessening the potential of doom in the event of this occurrence (pinched/and/or opened circuit keyed on/off switch wire(s).
After I found the evidence of pinched wire(s) the fix was simple.
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There is a US version of this on the NHSTA website. See attachment.
Zero doesn't seem to have released any new firmware yet though. The Zero website shows the last firmware was MBB41 with the page update of January 29, 2025. I just updated my 2023 DSR/X today.
Interesting to note that just 319 total number of potentially involved and the estimated percentage with defect is 0.6%.
https://static.nhtsa.gov/odi/rcl/2025/RCLRPT-25V587-9196.pdf
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Thanks for the doc. I would like to know if I can protect the harness to avoid damage in the future. As usual, my dealer is 300km away from me :(
The firmware was available and I did the update, but the doc says that the cable may eventually break if the bike is affected. It will be probably, as they fixed the routing in July 25.
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Well, how hard would it be for you to move it yourself? or see where exactly the point of failure is and maybe wrap it or something, tie it off out of the way or whatever you need to protect it? otherwise have to wait until you are in the area of the dealer again sadly.
aaron
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I am waiting for Zero to release some "how to fix" document, as they did with the brake hose line. Then once I know the exact spot I will try to fix it by myself :D