ElectricMotorcycleForum.com

Hi All,

I thought I would share the story of my experience with my 2017 Zero DSR with you just in case anyone has seen similar problems to me.

I live in the UK and I got the bike in March 2017.  I used it almost continuously (mostly commuting 50 miles a day) for a year with no issues, took it in for servicing when it needed it etc.  After about a year, the original tyres were looking a bit worn so I ended up changing them to road tyres.  I spoke to my dealer and they recommended a brand for me.  Incidentally, I think this added about 10% to the range and made for a much smoother ride. (130/80V17 AVON ROADRIDER, 100/90V19 AVON ROADRIDER)

I rode it for another year with no problems then just after the warranty ran out (isn't it always the way), I started having issues (maybe april(ish) 2019).

First the belt snapped (after only about 14k miles), which was not too much of a problem, I replaced it and carried on.  A few days later, I noticed (just once) that the front brake didn't work.  I tried to pull the lever and it was locked solid (the lever that is).  After a few more yards the brake released (with a sort of shuddering feel to the lever) and then everything was fine again.  I thought the front calipers might have been sticking, so I took then apart, checked them, put new pads in etc.  All seemed fine.  Then a few days later it happened again.

At this point, I contacted the dealer and explained what happened.  They arranged to take the bike in (they are some distance from me) and did some investigation.  Of course, they couldn't reproduce the problem and as a precaution (under advice from Zero) they replaced the master cylinder which I paid for.  I got the bike back and all seemed fine for a while until it happened again on the way to work.  Then when riding the bike back from work, I noticed that the ABS light was on.  I just happened to be looking at it when I used the front brake and the lever locking happened again.  This time I noticed that as that problem happened, the ABS warning light went out.

Of course, I passed this information onto the dealer and they took the bike back in.  Under Zero's advice they replaced the ABS pump.  This time, Zero did pay for it because they had given the advice to replace the master cylinder.  I got the bike back and all seemed fine for a month of riding.  Then one day, the bike stopped charging.  So off it went back to the dealer again to get the charger replaced.  In fairness to Zero, they covered the cost of the parts because of the other issues I had had with the bike.

I got the bike back and this time didn't even manage to ride it because the ABS warning light was on again.  So, back it went.  By now (I've missed out a lot of to-ing and fro-ing for brevity), it was getting to Winter.  Eventually, Zero said it must be because I have non-standard tyres on there.  I explained that (on and off) I had ridden the bike for 18 months or so with those tyres, a year of which I had no issues - note that the dealer doesn't understand this explanation either.  I sent the logs from the bike (which apparently just say "ABS SILA reporting an error") and Zero just insisted it is because of the tyres.  I asked the dealer if there would be any other issues, other than the ABS being disabled (remember the ABS system had been replaced at this point and since then the front brake locking hadn't happened).  They said, no it should be fine.  So I accepted their explanation that the tyres were the issue and thought I would ride with them until they needed changing and then put the 'official' tyres back to see if it solved the problem.

I was reasonably happy with that situation until (last night) going home, just riding the bike up onto my driveway (obviously there is a bit of a bump), the ABS light went off and the front brake lever locked up again.  I test rode it after that and the ABS light is staying on (as it has been since I got it back from the dealer the last time).  So, now I have a bike where (randomly) the front brake may or may not work one time when I pull the lever.

It certainly makes for an interesting Russian roulette experience when riding.

So, today, I am waiting again for a reply from Zero in order to work out what to do next.

I have to be honest, it has completely destroyed my confidence in Zero that they actually know how their own bikes work as I have never really had a satisfactory explanation as to what mechanism could cause this behaviour (Again, I have missed out a number of conversations in this explanation). Even if it is the tyres (which I don't believe), causing a critical failure in the front brake doesn't seem like the fail safe option.  Okay, disable the ABS but not the entire front brake.

I have sent emails to Zero directly but they just forward onto the dealer.

Does anyone on this forum have any ideas?

thanks,

Taf

One aspect is obvious from this problem and all others I've investigated, Zero has a nearly criminal attitude about Customer Service and resolving issues with their products.  AS in this instance they look everywhere but themselves for an "OUT", here the tire BS, rather than addressing the flaws in their products.  Bankruptcy is in Zero's future

Do you have the seat now?  Interested....

Wish I'd seen your bike before buying the 2023 Zero DSR 14.4!  Ergonomics on the Zero's is a nightmare of poor design and engineering, and Zero folks could not seem to care less.....

Word of caution on these manuals.  I downloaded the manual from Zero for my new 2023 DSR.  Searched for seat removal, found that their manual showed using your key to unlock the seat.  Problem is the 2023 DSR doesn't have a key lock for the seat.  Emailed Zero about this and they replied that the manual is for other versions and if I had only looked at changing fuses I would have seen how to remove my seat.............I have thoughts on this, do you?  Emblematic of Zero's customer care and skill at conducting themselves.  I smell bankruptcy in their future should they not get their stuff together and fast.  17K for a machine with BS manufacturer supplied manuals?