Most riders know the rule for helmets: replace them every five to seven years, no questions asked. But very few think about the quiet expiration date on the armor in their jackets and pants. That "like-new" leather you bought in 2012 may still look great—but the pads inside could be stiff, dried out, and far less capable of absorbing an impact than you think.
I’m Kristen Staggs, and after 25+ years in the motorcycle protection business Bohn has seen this mistake countless times. Motorcycle armor doesn’t last forever. Heat, sweat, UV, and simple aging slowly break down the materials that are supposed to cushion your elbows, knees, and back. If you never check or replace them, that once-soft armor can turn from a life-saving barrier into a brittle puck just when you need it most.
Your gear may look fresh, but aging armor often isn’t. Heat and sweat quietly weaken it until it can’t protect you anymore.
The good news? It’s easy to check, easy to replace, and with the right gear, your investment can last a decade.
Top Recommendations for Long-Lasting Protection
If you suspect your current armor is past its prime, or you want to upgrade to a system designed for longevity, here are the pieces I recommend:
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Bohn Replacement Armor: If your Bohn gear is older but the fabric is still in great shape, you don't need to buy a whole new outfit. We sell our CE-Level 2 SAS-TEC armor separately so you can refresh your protection instantly.
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Bohn Cool-Air Armored Shirt: This is the ultimate "buy once" investment. The armor is removable and reusable, and the shirt itself is designed to survive American heat while keeping that armor locked in place.
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Bohn All-Season Armored Pants: These feature our extended leg armor (covering knees and shins) and are built to last. Because they fit under your jeans, they aren't exposed to the sun and road grime that typically degrades outer layers.
3 Truths About Armor Lifespan (That Most Riders Ignore)
Before we dive into the science, let’s clear up a few misconceptions that might be putting you at risk.
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"If it looks fine, it is fine" is a dangerous myth.
Armor can look perfect on the outside while losing its chemical elasticity on the inside. I’ve seen armor that looks brand new but crumbles like dry cake when you bend it. You cannot rely on a visual check alone; you have to feel the material.
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Your sweat is an armor killer.
We often worry about rain or UV rays, but the salt and oils in your sweat are corrosive. If you never wash your armor (or the garment holding it), that buildup slowly breaks down the cellular structure of the foam, causing it to harden or lose its memory effect.
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Hard plastic armor isn't the "forever" solution you think it is.
Many riders think hard plastic shells last forever. While the plastic might look flexible and strong, it can dry out and become brittle over time, so even a small hit can shatter it. Meanwhile, the soft foam backing—the part that actually absorbs the energy so your bones don’t have to—also degrades. If that backing fails, the hard shell simply transmits the shock straight to your body.
The 10-Year Advantage: Why Material Matters
Not all armor is created equal. Many generic foam pads found in budget gear have a lifespan of only 2–3 years before they start to degrade. This is often because they are made of cheaper polyurethane blends that dry out quickly.
At Bohn, we use SAS-TEC viscoelastic foam. One of the massive benefits of SAS-TEC is its stability. The manufacturers of our armor state a life expectancy of up to 10 years.
Motorcycle armor expires—cheap foam can fail in 2–3 years. Bohn’s SAS-TEC armor stays protective and reliable for up to 10 years.
This is a huge differentiator. It means that when you buy a set of Bohn Body Armor, you aren't just buying protection for this season; you are making a 10-year investment. As long as you take care of it and don't damage it in a crash, that armor will retain its impact-absorbing properties far longer than standard foam.
The "Squish Test": How to Check Your Gear
So, how do you know if your current gear is expired? You need to perform a tactile inspection.
Take the armor out of the pocket (this is crucial—don't try to feel it through the fabric). Squeeze it firmly between your thumb and fingers.
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Good Armor: It should feel firm but pliable. When you bend it, the material should stay consistent in color and texture. It should return to its original shape after squeezing.
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Bad Armor: If it feels rock hard, brittle, cracks when squeezed, flakes in your hand, or turns lighter in color when bent, it’s done. Replace it immediately.
Armor Lifespan Rule of Thumb:
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Armor bought before 2024: expect 5–7 years of usable life
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Armor bought after 2024 from reputable manufacturers: up to 10 years
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When in doubt — throw it out.
Your protection is only as good as the material inside your jacket.
Why Armor Coverage Is Critical for Longevity
One reason we are so obsessive about armor size—using 5 x 12-inch elbow/forearm pads and 5.25 x 12-inch knee/shin pads—is that larger surface area distributes force better.
In a crash, a small, degraded pad might shatter or shift. Our larger SAS-TEC pieces cover the entire joint and the surrounding bone (like the ulna and tibia). This massive coverage means that even as the armor ages within its 10-year window, you have a substantial protective barrier that isn't relying on a tiny, quarter-sized sweet spot to work.
Modularity: The Bohn "Forever" System
The beauty of the Bohn system is that it separates the armor from the fashion.
If you buy a dedicated motorcycle jacket with sewn-in armor, and that jacket fades or the zipper breaks, you often have to toss the whole thing—armor included. With Bohn, the armored shirt and pants are your base.
Let’s say you lose 20 pounds (good for you!) and your Bohn shirt is now too big. You don't need to buy a whole new set of armor. You can buy just the fabric shell from us for a fraction of the price and transfer your existing SAS-TEC armor into the new shirt.
Motorcycle armor expires. Learn why generic pads fail in 2–3 years and how Bohn’s SAS-TEC system protects you for up to a decade.
Or, perhaps you’ve been riding for 10 years and your fabric is fine, but the armor has reached its expiration date. You can simply buy a replacement armor set and slide it into your trusty Bohn shirt. This modularity saves you money and ensures you never have an excuse to ride with expired protection.
Frequently Asked Questions
Does Bohn armor expire if it’s never been used?
Yes, eventually. Even if it’s sitting in a box, the materials can slowly age due to oxidation, though it happens much slower than if it were being used. However, SAS-TEC is robust; if stored in a cool, dry place, it can easily reach that 10-year mark.
Can I wash my armor?
SAS-TEC’s molded viscoelastic armor absorbs less than 1% moisture, so hand washing is perfectly safe and recommended. Use mild soap and water, rinse it well, and let it air dry. Keeping it clean removes sweat and salts that can degrade the foam over time.
However, fabric-backed SAS-TEC armor can retain moisture, so it should be dried thoroughly after washing. Always check which type your gear uses before cleaning.
If I crash, do I need to replace the armor?
SAS-TEC is "multi-impact compliant," meaning it can withstand an impact and return to its original shape, unlike Styrofoam helmet liners which are "one and done". However, if you have a significant crash, you should always inspect the armor. If there are tears, deep gouges, or if it feels different, replace it. It’s better to be safe than sorry.
How do I dispose of old armor?
One of the cool things about SAS-TEC is that the raw materials are partially renewable, and it can be disposed of with regular household garbage. It’s environmentally compatible, unlike some complex plastic composites.
Why does my old armor feel hard in the winter?
Viscoelastic foam is temperature sensitive. It might feel stiffer in the cold and softer in the heat. This is normal! Your body heat will warm it up and make it pliable within a few minutes of putting it on. It's always a good rule of thumb to warm your armor up on your body before getting on the bike as well. Armor that is too cold can crack at the articulations.
Is older armor better than no armor?
Technically, yes, something is usually better than nothing. But "better than nothing" isn't the standard we aim for at Bohn. We aim to mitigate injury." Old, brittle armor might crumble on impact, offering virtually zero energy absorption. Don’t gamble your knees on a 15-year-old piece of foam.
Does the fabric of the shirt expire?
Fabric doesn't "expire" chemically like foam, but Lycra™ and elastic can eventually lose their stretch. If your Bohn shirt no longer fits snugly, the armor might shift during a crash. If the elastic is shot, it’s time to replace the shell to ensure that 5 x 8-inch shoulder armor stays exactly over your shoulder.
Final Thoughts
We design our gear in the USA to be the most comfortable protection you’ve ever worn, but we also design it to be a long-term partner in your riding life. Check your gear today. Give it the squeeze test.
If it’s time for a refresh, we’re here to help you get back on the road with confidence. If you want to replace or upgrade your armour, you can find dozens of options and sizes here to suit you.
