Zero Motorcycles is recalling all 2012 Zero S and DS models as well as the DSP police bike, because of a problem that can cause an electrical short in the battery, creating a fire risk. Due to the nature of the issue, Zero will be buying back all models from owners, or offer a financial trade-assist towards a newer model. The recall affects 218 units in the U.S.
According to documents released by the National Highway Traffic Safety Administration, the cell pouches in the battery packs of the affected models were designed in such a way that they could move within their holders. Through regular wear, this may cause a breach in the outer layers of the cell pouches. Humidity can thus penetrate the pouches, leading to cell separator decay and allowing an internal short within the cell, creating the potential for what Zero calls a “thermal event” (i.e. fire). Motorcycles affected by this problem may exhibit a significant decrease in power and range.
The problem was first reported in July 21, 2016 after an S model converted for police use in Hong Kong experienced a “thermal event” while charging. According to the South China Morning Post, a pair of S models were charging at the Ngau Tau Kok police station when one of them caught on fire at 1:15 am local time. The fire damaged both motorcycles as well as a nearby police van, but no one was injured.
Zero hired a battery technical expert to examine the affected motorcycle as well as the rest of the police dep...