October 15, 2020 NHTSA CAMPAIGN NUMBER: 20V640000
DC Converter Has Insufficient Power Output
The DC-DC converter can shut off when its power capacity is exceeded, shutting off the ABS, instruments, and lights, increasing the risk of a crash.
NHTSA Campaign Number: 20V640
Manufacturer Zero Motorcycles Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 64
Summary
Zero Motorcycle Inc. (Zero) is recalling certain 2021 SR, S, DSR, DS, FX, and FXS motorcycles. The DC-DC converter has an insufficient power output margin to operate the anti-lock braking system (ABS), instruments, lights, indicators, and any accessories that are connected to the accessory outlet at once.
Remedy
Zero will notify owners, and dealers will replace the DC-DC converter, free of charge. The recall began October 26, 2020. Owners may contact Zero customer service at 1-888-841-8085. Zero’s number for this recall is SV-ZMC-021-019.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.
Date:
October XX, 2020
Safety Recall: 2021 DC-DC Converter NHTSA Campaign Number: 20V-640
Purpose
Zero Motorcycles has determined that a defect, which relates to motor vehicle safety, exists on certain 2021 Model Year SR, S, DSR, DS, FX and FXS model motorcycles built between August 19, 2020 and October 5, 2020. The subject motorcycles were assembled with a DC-DC converter that may have insufficient power output margin. If a DC-DC converter does not have enough power output margin to support all power demands, it may temporarily shut off when its power capacity is exceeded, with no warning to the rider. Should this occur during an Anti-Lock Braking System (ABS) activated event, the ABS and all vehicle lights would temporarily stop functioning, which could increase the risk of a crash.
In the interest of motor vehicle safety and customer satisfaction, Zero Motorcycles has elected to initiate a voluntary recall (Campaign 20V-640) to remedy this defect. The remedy of this defect is to have Zero Motorcycles dealers replace the revision B DC-DC converter with a revision A
As required by law, you may sell but NOT DELIVER any affected motorcycles to your customers until the remedy is completed.
Applicable Models
The recall population of 64 motorcycles includes selected 2021 model year Zero SR, S, DSR, DS, FX and FXS built between August 19, 2020 and October 5, 2020.
Owner Notification
In accordance with Federal regulations administered by NHTSA, Zero Motorcycles will send a letter to registered owners of affected motorcycles, notifying them of this safety-related condition and instructing them to contact their dealer for the associated remedy. A sample of the owner letter is attached. Zero will also try to contact these customers via email.
To protect the safety of our riders, it is our mutual responsibility to ensure the recall upgrade is performed on all affected motorcycles. Therefore, we strongly encourage you reach out to your customers to make sure that they are aware of this program. You are also required by law to perform the recall service on all affected motorcycles in your inventory prior to delivery to your customers.
If you are aware of any unregistered owners of this affected motorcycle population, please advise us of their names, addresses and VINs, so that we may mail them the owner’s letter, as required by NHTSA.
If you are not sure that this safety recall has been performed on a particular motorcycle, please contact Zero Motorcycles Customer Service for verification.
Sample Owner Communication
IMPORTANT SAFETY RECALL NOTICE
This notice applies to your vehicle VIN# XXXXXXXXXXX
November XX, 2020
Dear Zero Motorcycles Owner,
This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Zero Motorcycles has determined that a defect, which relates to motor vehicle safety, exists on certain
2021 Model Year SR, S, DSR, DS, FX and FXS model motorcycles built between August 19, 2020 and October 5, 2020. The subject motorcycles were assembled with a DC-DC converter that may have insufficient power output margin. If a DC-DC converter does not have enough power output margin to support all power demands, it may temporarily shut off when its power capacity is exceeded, with no warning to the rider. Should this occur during an Anti-Lock Braking System (ABS) activated event, the ABS and all vehicle lights would temporarily stop functioning, which could increase the risk of a crash. Zero Motorcycles has voluntarily initiated this recall to correct this condition.
Our records indicate that you purchased one of the motorcycles listed above.
We strongly urge you to contact your Zero Motorcycles dealer to make arrangements to have the appropriate service performed as soon as possible. Should you choose to ride your motorcycle prior to this service, we urge you to be aware of this condition.
The remedy of this defect is for a Zero Motorcycles authorized dealer to replace the incorrect revision B DC-DC converter with the correct revision A, which is designated in writing on the label. Should you choose to ride your suspect motorcycle prior to having your dealer perform this replacement, you should be aware of this condition and avoid running any accessories on the accessory outlet.
Please contact your Zero Motorcycles dealer immediately and arrange an appointment to have your motorcycle repaired. The actual dealer labor time to perform this service will be approximately 1 hour and 30 minutes; however, due to scheduling, the dealer may require your motorcycle for a longer period. The parts and labor will be free of charge to you. Replacement parts are now available for order by your dealer.
If you no longer own this motorcycle, please contact us at 1-888-841-8085 so we may update our records and notify the new owner. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
If you have had this defect repaired before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall. For more information contact Zero Motorcycles at 1-888-841-8085.
If your dealer or Zero Motorcycles fails or is unable to remedy your motorcycle without charge within a reasonable time, you may wish to inform the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call the toll-free hotline at 1-888-327-4236 (TTY: 1800-424-9153); or contact NHTSA at https://www.safecar.gov.
We value safety above all else and strive for the highest standards in ride quality and experience, and we deeply regret this inconvenience. Zero Motorcycles would not be issuing this action if it were not in the interest of your personal safety, satisfaction and enjoyment of your Zero motorcycle. Thank you for your understanding, and we look forward to a swift and smooth remediation of this issue.
Sincerely,
Aaron S. Cheatham
VP of Customer Experience
Zero Motorcycles, Inc.
Tools Required
Controller Discharge Tool (p/n 85-05665)
3mm hex wrench
4mm hex wrench
5mm hex wrench
10mm wrench
Philips screwdriver
Parts Required
500W DC-DC CONV SEVCON REV A (p/n 60-07190-01)
Procedure
Caution: Always perform the High Voltage Discharging procedure prior to servicing any High Voltage component or connection. Proper procedures must be followed!
The procedure for the replacement of a DC-DC converter differs based on the applicable model. Please refer to the 20MY or 21MY Service Manual, which have the same procedures, available at the service.zeromotorcycles.com website under the applicable model for full details.
The correct Revision A DC-DC converter can be distinguished from the incorrect Revision B DC-DC converter by examining the label on the silver, slotted bracket end of the components. See pictures below.
| Correct Revision A | Incorrect Revision B |
 |  |
Please ensure the incorrect Rev B DC-DC converter is marked to avoid potential mix-up and contact the Zero Motorcycles Customer Service or Aftersales team to have a call tag generated to support the return shipment of the replaced converter to Zero Motorcycles.
Timing and Reimbursement
To receive reimbursement for the work performed and parts used under this service campaign, the dealer must submit a warranty claim for the replacement costs incurred that includes the following information:
- Warranty Claim Type: Service Campaign/Recall
- Fault Summary: 2021 DC-DC Converter Recall
- Fault Area: 50–DC/DC Converter
- Fault Code: 91-Service Bulletin Recall
See the example below for full details.
Zero Motorcycles believes that the time that should be allotted to this work is 90 minutes (1.5 hours). We do not reimburse any costs related to loaner or temporary replacement motorcycles or other vehicles.
Questions
Please contact the Customer Service or Aftersales Teams with any questions:
Customer Service Team, Americas and ROW
Phone: (888) RUN-ZERO Ext. 2 / (888) 786-9376 Ext. 2
Email: [email protected]
Team members include: Allison Seibert, Buffi Warner, Jesse Rodriguez, Matt Johnson, Sam Ritzo and Vinicius DaSilva
Aftersales Team, Americas and APAC Contact Information
Phone: (888) RUN-ZERO Ext. 8 / (888) 786-9376 Ext. 8
Email: [email protected]
Team members include: Carli Saccomano and Nicholas Bradfield
6 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| ZERO | DS | 2021 |
| ZERO | DSR | 2021 |
| ZERO | FX | 2021 |
| ZERO | FXS | 2021 |
| ZERO | S | 2021 |
| ZERO | SR | 2021 |
8 Associated Documents
Recall Acknowledgement
RCAK-20V640-3984.pdf 302.135KB
Manufacturer Notices(to Dealers,etc)
RCMN-20V640-2028.pdf 160.114KB
Recall Quarterly Report #1, 2020-4
RCLQRT-20V640-9300.PDF 211.149KB
Recall Quarterly Report #3, 2021-2
RCLQRT-20V640-6667.PDF 211.331KB
Recall 573 Report-Amendment 1
RCLRPT-20V640-9393.PDF 215.914KB
Recall Quarterly Report #2, 2021-1
RCLQRT-20V640-5981.PDF 211.248KB
Owner Notification Letter(Part 577)
RCONL-20V640-0874.pdf 112.367KB
Recall Quarterly Report #4, 2021-3
RCLQRT-20V640-4974.PDF 211.434KB
Latest Recalls Documents
- Flex Level 1 EV Charger - The EVDANCE Level 1 electric car charger is compatible with J1772 electric vehicles and plug-in hybrid
vehicles (North American Standard). *Tesla requires a SAE J1772 adapter. - Convenient to Use - This charger has both NEMA 6-20 plug for 16A 240V charging (3.68kW, 10-12 mi/h) and a NEMA 6-20 to 5-15 plug adapter for 12A 120V charging (1.44kW, 2-5 mi/h). The included bag makes it easier to carry on the go. It also has a 25ft cable length, you can use it flexibly from anywhere in the garage or driveway.
- Check Your Outlet Type -This charger works with standard 120V NEMA 5-15/5-20 outlets (2-5 mph charging speed) and 240V NEMA 6-20 outlets (10-12 mph) . It's not compatible with NEMA 6-15/10-30/14-30/14-50/6-50 outlets – you'll need a NEMA 14-50/14-30/10-30/6-50 to 6-20 adapter (sold separately) to connect.
- Compatible EV Models -This EV charger works with most major electric vehicles, including Ford, Chevrolet, Hyundai, Audi, Nissan Ariya, Rivian R1S, Kia, and others. However, it's not compatible with Mini Cooper Electric Hardtop,Toyota Prus Prime/Z4X/RAV4Prime, Porsche Taycan Base/4S/Turbo/Turbo S or Tesla models (Tesla requires a J1772 to Tesla Adapter, sold separately). For a full list of compatible models, check out the Full Compatibility List on our product page.
- Indication Displays - LED display that can tell you the status as well as indicate errors while charging your electric vehicle.
vehicles (North American Standard). *
- WORKS WITH EVERY NON-TESLA EV: Standard J1772 connector plugs straight into Ford, Chevrolet, Hyundai, Kia, Nissan, BMW, Volkswagen, Audi, Rivian, Lucid and every other EV or plug-in hybrid sold with a J1772 port - no adapter needed. Tesla drivers can charge too, using the J1772 adapter that comes with the car.
- PLUG IN, NO HARDWIRING: Level 2 charger delivers up to 40A to fully charge most EVs overnight. Plugs into a 240V, 4-prong NEMA 14-50 outlet (the RV/range type - NOT a dryer outlet) on a dedicated 50A circuit. The extra-long 25 ft cable easily reaches across a garage or driveway. Before ordering, check your car's port type and that you have the right outlet.
- CONTROL & SAVE FROM YOUR PHONE: A stronger built-in antenna keeps the charger online even in a garage or basement. Use the free app to start/stop charging, set speed (6-40A), get reminders, and track energy use and cost. Schedule off-peak overnight charging to cut your electric bill. Requires 2.4 GHz WiFi.
- SAFETY-CERTIFIED & WEATHERPROOF: Independently tested and certified (UL, ETL, FCC, Energy Star). A fully sealed IP66 / NEMA 4 housing stands up to rain, snow, heat and dust indoors or out, and internal steel shielding protects the electronics for years of reliable use.
- GLOW-IN-THE-DARK HOLSTER: The included high-visibility holster glows in the dark so you can find and dock the plug easily at night. Holds the connector securely when not in use.
- [2026 INTELLIGENT CHARGING UPGRADE — PRECISION CONTROL MEETS SMART SCHEDULING] After surveying 100K+ U.S. EV owners, the Raylix R&D team found that nearly all drivers recognized the necessity of adjustable current and scheduled charging. Our upgraded J1772 charger features 4-level adjustable current (8A/10A/12A/16A) and a 1–12 hour smart delay timer. Whether you're charging overnight or during off-peak hours, enjoy smarter energy use, lower costs, and total convenience—on your schedule.
- [ONE CHARGER, ALL J1772 EVs/PHEVs READY!] Compatible with all SAE J1772 electric vehicles and plug-in hybrids—whether it’s Ford, GM, Nissan, Audi, BMW, Kia, Hyundai, Honda, Chevy, or more. Perfect for home or on-the-road charging, our 16A Level 1 & 2 charger ensures your EV is always powered and ready for any journey.
- [CHARGE 4× FASTER — NO MORE WAITING] In a rush? Our 16A Level 1 & 2 charger delivers charging speeds up to 4× faster than standard 8A Charger Level 1. Whether it's an early commute, a spontaneous trip, or last-minute errands, your EV will be ready when you are.
- [LEVEL 1 & 2 PORTABLE CHARGER — CHARGE ANYWHERE, ANYTIME] Designed for maximum flexibility, Raylix Level 1 & 2 EV charger features both 5-15 and 6-20 plug compatibility. Whether you're charging in your garage, at a friend's house, or at a roadside motel. NEMA 6-20 plug for Level 2 ev charging (240V, 16A, 3.68kW, 9-12 miles/hr) and a NEMA 5-15 adapter for Level 1 ev charging (120V, 12A, 1.44kW, 3-5 miles/hr) NOTE: In compliance with North American electrical safety standards, the charger automatically limits current to 12A when using a 5-15 outlet—protecting both your vehicle and your home’s electrical system.
- [AT-A-GLANCE CHARGING COMMAND: TOTAL CONTROL, INSTANTLY] While most ev chargers solutions confine vital data to in-car screens, the Raylix tesla charger breaks free with its enhanced TFT color display. This Raylix-exclusive feature delivers crystal-clear, real-time updates—voltage, current, power load, AND critical charging temperature—directly on the unit. Just one glance gives you complete charging insight. It’s not just information; it's the empowering peace of mind and satisfying control that transforms every charge into a masterfully managed experience.
- [Up to 9x Faster Charging Speed]: Provides up to 46 miles/hour charging speed via hardwired connection (48 amp - up to 9x faster than a standard wall outlet) or up to 38 miles/hour via the NEMA 14-50 plug (40 amp). Professional installation recommended for optimal safety and performance. [Install The Power Outlet Cord]: No smaller than 8AWG if charge 40-48A, we suggest 6AWG cord.(1.The input side is belongs to the electrician electric automobile regulation scope, need to use three 6AWG cable wires for 48A; 2.The charging cable belongs to the automotive connector certification standard, so the 8AWG cable can meet the 48A.)
- [DESIGNED WITH J1772 Connector for All North America j1772 Connector EVs/PHEVs. Not fits for Tesla/Nacs Connector Cars(j1772 to Tesla adapter needed)]: Compatible with Tesla cars (Adapter needed, not included), Ford, GM, Audi, Kia, Honda, Kia, Hyundai, Gmc, Chevrolet Bolt, VW ID 4, Nissan Leaf, Ford Mustang Mach-E, IONIQ 5 2024 and before, BMW i3, i4, iX, Jeep Wrangler 4xe, etc. [Not fits for Nac connector cars-Kia EV6 2025/EV9,Ariya 2025&2025 loniq 5(J1772 to Tesla adapter needed)]
- [Safety & Faster Charging with ETL, FCC, Energy Star Certified]: Meets the Safety Criteria Defined by: SAE J1772, UL2231-1/-2, UL 991, UL 2231, UL 2251, UL1998 and UL 2594. (ETL and FCC certified EV car charger with 3-year Warranty)
- [Plug-play Mode(The Default Setting), Smart Touch Screen, No APP Needed]: Clearly show the charging amperage, charging speed, input voltage, delay time, etc. For the touch buttons: 1. Pull out the charging gun before press the buttons, otherwise no respond; 2. Long press "Ⓐ" or "Time" button to enter the setting interface, then you can adjust the amperage from 16A to 48A freely or Set the charging start time; 3. You can do "factory reset" if doesn't charging.
- [Smart WIFI APP, You can Set the Charging Period]: By APP, you can wirelessly check the charging cost, history, fully-charged notification, track the charging status, during off-peak period, etc. [Wi-Fi Reset/Factory Reset Function, Add New Device Quickly]: If you can't find your device or you have replaced a new phone, just pull out the charging latches, simultaneously long press the Ⓐ button and time adjustment button on the product screen until it shows "Factory Reset", then wait 3-5 seconds and re-start your device.
- WORKS WITH EVERY NON-TESLA EV: Standard J1772 connector plugs straight into Ford, Chevrolet, Hyundai, Kia, Nissan, BMW, Volkswagen, Audi, Rivian, Lucid and every other EV or plug-in hybrid sold with a J1772 port - no adapter needed. Tesla drivers can charge too, using the J1772 adapter that comes with the car. The extra-long 25 ft cable easily reaches across a garage or driveway.
- HARDWIRED - PROFESSIONAL INSTALL: This Level 2 charger is hardwired (not plug-in), so a licensed electrician installs it per National Electrical Code. It delivers up to 48A on a dedicated 60A, 240V circuit - enough to charge most EVs fully overnight. Want more speed? You can set DIP switches 4 and 5 to unlock 50A on a dedicated 70A circuit. Before ordering, check your car's port type and that your electrical panel can support the circuit.
- CONTROL FROM YOUR PHONE: A stronger built-in antenna keeps the charger online even in a garage or basement. Use the free app to start and stop charging, set the charging speed (6-48A), get reminders, and track how much energy and money each charge uses. Requires a 2.4 GHz home WiFi network.
- SAFETY-CERTIFIED & WEATHERPROOF: Independently tested and certified (UL, ETL, FCC, Energy Star). A fully sealed IP66 / NEMA 4 housing stands up to rain, snow, heat and dust indoors or out, and internal steel shielding protects the electronics for years of reliable use.
- GLOW-IN-THE-DARK HOLSTER: The included high-visibility holster glows in the dark so you can find and dock the plug easily at night. Holds the connector securely when not in use.
This product presentation was made with AAWP plugin.