Recall 20V640 affects 64 2021 Zero Fxs, Ds, S, Fx, Dsr, and Sr motorcycles for DC-DC shutdown. Repair is free at any franchised Zero dealer.
Zero is recalling 64 2021 Fxs, Ds, S, Fx, Dsr, and Sr motorcycles because the DC-DC converter can be overloaded when the ABS, instruments, lights, indicators, and accessory outlet draw power at once. If the converter shuts off, ABS, instruments, and lights turn off, increasing crash risk; Zero dealers will complete the repair free of charge.
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What's wrong?
The DC-DC converter on the 2021 Zero Fxs, Ds, S, Fx, Dsr, and Sr motorcycles is the electrical part that feeds lower-voltage power to key systems while the motorcycle is running. It supports the anti-lock braking system, instruments, lights, indicators, and anything plugged into the accessory outlet, so those systems have power at the same time.
On affected motorcycles, a Revision B converter was installed where Zero intended the Revision A converter. The supplier shipped the Revision B part with improper labeling, and it was used during motorcycle assembly under the wrong part number. That converter does not have enough power output margin when the ABS, instruments, lights, indicators, and accessory outlet are all drawing power.
There is no warning sign before failure. An owner should not rely on a dashboard message, unusual light behavior, or brake feel to identify this issue before the converter is overloaded.
Who's affected?
Covers the Fxs, Ds, S, Fx, Dsr, and Sr models with the same electric propulsion system component.
| 2021 Zero Fxs | electric propulsion system |
|---|---|
| 2021 Zero Ds | electric propulsion system |
| 2021 Zero S | electric propulsion system |
| 2021 Zero Fx | electric propulsion system |
| 2021 Zero Dsr | electric propulsion system |
| 2021 Zero Sr | electric propulsion system |
| Units affected | 64 |
| Field incidents | NHTSA has logged no field incidents to date. |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific motorcycle is included.
What's the safety risk?
If the DC-DC converter shuts off after its power capacity is exceeded, ABS, instruments, and lights stop working, which increases crash risk. There is no warning sign before the shutdown. Schedule the recall repair soon and use extra caution until it is complete. Repair is free at any franchised Zero dealer.
What should I do?
- Check your VIN to confirm your 2021 Zero Fxs, Ds, S, Fx, Dsr, or Sr is included in this recall.
- Contact a franchised Zero dealer to schedule the free DC-DC converter replacement that restores power margin for the ABS, instruments, lights, indicators, and accessory outlet.
- Bring the recall notice if Zero mailed one. Reference recall number 20V640 when you call.
- Avoid accessory-outlet loads until the repair is complete, and stop in a safe place if ABS, instruments, or lights shut off while riding.
What happens at the repair
At the dealer, a Zero technician replaces the DC-DC converter, the part that supplies power for the ABS, instruments, lights, indicators, and accessory outlet. The replacement parts and labor are free under the recall, and this dealer remedy is available now. Zero has a general reimbursement plan on file. If you already paid out of pocket for a related DC-DC converter repair before the recall work, contact Zero customer service or ask the service desk how to submit documentation under that plan.
| Reimbursement | Reimbursement available |
|---|
Timeline
| October 15, 2020 | NHTSA published the recall |
|---|---|
| October 26, 2020 | Dealer notification began |
| October 26, 2020 | Owner notification mailed |
| November 2, 2020 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| November 2, 2020 | Interim owner notification (was planned for this date) |
| November 9, 2020 | Dealer notification ended |
Frequently asked questions
What is recall 20V640?
Recall 20V640 covers 64 2021 Zero Fxs, Ds, S, Fx, Dsr, and Sr motorcycles with a DC-DC converter that can lose power when demand is too high. That can shut off ABS, instruments, and lights, increasing crash risk.
What should I do if my 2021 Zero Fxs, Ds, S, Fx, Dsr, or Sr is on this recall?
Check your VIN to confirm your specific motorcycle is included in recall 20V640. If it is, contact a franchised Zero dealer to schedule the DC-DC converter replacement. Reference recall number 20V640 or Zero recall number SV-ZMC-021-019 when you call.
Is the recall repair free?
Yes. Zero's remedy says dealers will replace the DC-DC converter free of charge. Federal recall law also requires the manufacturer to perform the recall repair at no cost at a franchised Zero dealer.
What is the safety risk?
The DC-DC converter can shut off when its power capacity is exceeded. If that happens, ABS, instruments, and lights can turn off while riding, increasing the risk of a crash. The dealer repair replaces the converter for free.
When did the Zero recall repair start?
Zero began the recall on October 26, 2020. The remedy is available, so owners whose VINs are included can contact a franchised Zero dealer for the free DC-DC converter replacement.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/20V640000 |
|---|---|
| Zero customer service | 1-888-841-8085 |
| NHTSA recall # | 20V640 |
| NHTSA recall # (full) | 20V640000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Quarterly Report (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 23, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →