Trying to stay dry on a motorcycle is a battle every long-distance rider eventually fights. You want a jacket that keeps the rain out but also keeps you cool when the sun finally peeks through the clouds. At Bohn, we have spent more than 25 years helping riders find the right balance between weather protection and safety without feeling like they are wearing a heavy diving suit.

If you buy a bulky all-in-one waterproof jacket, you often end up soaked in sweat because the fabric cannot breathe fast enough. It is a miserable feeling to be damp and cold for hours; so we built an armor system that allows for a highly packable system that fits all weather conditions. When you get your gear right, a sudden rainstorm becomes just another part of the story instead of a reason to pull over and quit.

This guide will explain why the "perfect" waterproof jacket might not exist as a single garment. We will look at how to use breathable base layers and rain shells to build a setup that handles any weather.

Waterproof jackets often leave you soaked in sweat. Bohn's solution: breathable armor base layer + rain shell only when you need it.

What a Waterproof Motorcycle Jacket Offers

The motorcycle gear industry has spent decades trying to build the "perfect" waterproof jacket - one that keeps rain out, lets sweat escape, and protects you in a crash. Below, we'll examine what leading brands offer and why many riders are moving to a layering system instead.

Klim

Klim represents the premium end of adventure touring gear, with jackets like the Klim Badlands Pro in the $800-$1,000 range. These jackets feature Gore-Tex Pro waterproofing, extensive ventilation systems, and high-quality D3O armor that's among the best in the industry.

The Badlands Pro excels at weather protection with fully taped seams and a reliable waterproof membrane that actually works in downpours. The jacket includes multiple vents, pockets for hydration systems, and tough Cordura construction for serious adventure riders.

However, even at $1,000, you're still dealing with the fundamental compromise: the waterproof membrane that keeps rain out also traps your body heat inside. On hot days between rainstorms, the jacket becomes a sweat trap. 

Also, the armor sits in large pockets to accommodate the jacket's bulky construction, which means it can shift during impacts. The jacket is also heavy and exhausting to wear for 8+ hour days.

Top-tier adventure gear with reliable rain protection. Even at $1,000, membrane traps sweat, armor floats, heavy for 8+ hour days.

Klim makes exceptional adventure gear for serious touring. But the all-in-one design means you're either too hot or too wet, with armor that doesn't stay body-fitted.

Rev'It

Rev'It offers excellent mid-to-premium waterproof options like the Rev'It Defender 3 GTX in the $600-$800 range. These jackets use Gore-Tex membranes with European styling and good build quality, making them popular among sport-touring and adventure riders.

The Defender series features laminated Gore-Tex construction where the waterproof layer is bonded directly to the outer shell, reducing bulk compared to drop-liner designs. You get CE-Level 1 armor standard with upgrade options, multiple adjustment points, and reflective detailing.

Excellent build quality with bonded Gore-Tex reducing bulk. Even laminated design traps sweat, heavy for summer, armor floats loose.

The trade-off is that even laminated construction still traps heat and sweat on warm days. The jacket's European sizing runs small, and the armor pockets are still loose-fitting rather than body-close. At 4-5 pounds, the jacket is tiring to wear during long summer rides when you're just hoping it doesn't rain.

Alpinestars

Alpinestars makes reliable waterproof jackets like the Alpinestars Andes v3 Drystar in the $400-$600 range. The Drystar membrane is Alpinestars' proprietary waterproofing technology, and these jackets offer solid weather protection at more accessible prices than Gore-Tex options.

The Andes v3 features good ventilation for a waterproof jacket, with multiple zippered vents and removable thermal liners for temperature adjustment. The jacket includes CE-Level 1 armor and plenty of pockets for touring essentials.

Alpinestars offers accessible waterproof protection with removable liners. Still bulky, armor pockets loose, less breathable membrane.

However, the Drystar membrane is less breathable than Gore-Tex, meaning you'll sweat even more on hot days. The jacket's touring fit is quite bulky to accommodate all the layers and liners, and the armor floats in large pockets. The removable liner system adds complexity - you're constantly adding or removing layers trying to regulate temperature.

The Bohn Layering Solution

After reviewing the waterproof jacket market, you'll notice a pattern: every all-in-one waterproof jacket makes the same fundamental compromises. They're hot when you don't need waterproofing, heavy all the time, and the armor sits in loose pockets that compromise safety.

The Bohn layering system solves this by separating three distinct functions:

1. Impact protection: Bohn armored shirt with body-fitted SAS-TEC CE-Level 2 armor

2. Abrasion resistance: Your choice of outer layer (denim, leather, textile)

3. Weather protection: A lightweight packable rain shell you add only when needed

Wear a Bohn Cool-Air or Airtex Armored Shirt as your base layer - it's breathable mesh and Lycra™ that keeps SAS-TEC armor locked against your joints. When rain threatens, pull a simple $50-$100 rain jacket from your saddlebag over everything.

Separate impact, abrasion, weather. Bohn base locks armor to body, add packable shell only when raining. Protected always, hot never.

This approach means you're cool and comfortable 90% of the time, protected 100% of the time, and you only add waterproofing when you actually need it. The rain shell can be thin and packable because it doesn't need to hold armor or provide impact protection - those jobs are handled by your Bohn layer.

Total investment: 

• $200-$300 for a Bohn armored shirt plus a quality rain shell

• Versus $400-$1,000 for an all-in-one jacket that's always too hot and has armor that shifts.

Top Recommendations for Riders in the Rain

Bohn Airtex Armored Shirt

This is the foundation of a great waterproof setup for most riders. It is a breathable base layer made of Lycra™ and mesh that holds your SAS-TEC armor tight against your body. Because the armor is attached to you and not your outer jacket, you can wear any simple rain shell over the top and still have your impact protection exactly where it belongs.

Get Bohn Airtex Armored Shirt

Bohn Cool-Air Armored Shirt

If you ride in places where it is both hot and rainy, like Florida or the Gulf Coast, this is your best friend. It features a very open mesh that allows maximum airflow to reach your skin as soon as the rain stops and you take your shell off. It keeps your shoulders, elbows, and back shielded while preventing you from overheating during those humid summer storms.

Get the Cool-Air Mesh Shirt

Bohn Armored Mesh Pants

Rain often hits your legs the hardest, and standard waterproof pants rarely have armor that fits well. These mesh pants fit right under your favorite riding jeans or even a pair of waterproof over-pants. They feature SAS-TEC CE-Level 2 armor for your knees, shins, and hips, with extra armor for the thigh and tailbone, ensuring you stay protected even if the road gets slippery. That thigh and tailbone armor is the same material as the rest, but CE doesn’t have a rating for these areas!

Get All-Season Armored Pants

3 Truths About Motorcycle Gear (That Might Surprise You)

1. The First Bounce Is the Critical Moment

Most people think about sliding down the road, but the initial impact is often what causes the most damage to your body. Protecting your joints and bones from that first hard hit should be your top priority when picking gear. We focus on using high-quality SAS-TEC material to help manage that energy before you even begin to slide.

2. Armor That Moves Is Armor That Fails

If your waterproof jacket is baggy, the armor inside will shift or rotate away from your joints during a fall. For armor to work, it has to stay between you and the ground at the exact moment of impact. This is why a body-close fit for your armor is more important than the style of your outer jacket.

3. Being Uncomfortable Makes You Less Safe

When you are shivering from the cold or boiling in a thick plastic jacket, your reaction time slows down significantly. You stop looking as far ahead and start focusing on your own misery, which is a dangerous way to ride. Gear that keeps you comfortable and at the right temperature helps you stay sharp and aware of your surroundings.

Why the All-in-One Approach Struggles

The pursuit of a "do-it-all" motorcycle jacket creates a fundamental conflict between protection, comfort, and weatherproofing. Waterproof membranes, while effective at blocking rain, inevitably trap body heat and moisture against the rider's skin. Even in moderate temperatures, this lack of airflow leads to excessive sweating that makes the rider as wet as the rain would have.

The physical construction of these jackets further compromises the rider's endurance and safety. Because they must integrate waterproofing and abrasion resistance into one piece, the garments become heavy and bulky, physically draining the rider over long distances. This cumulative fatigue is a significant safety hazard, as an exhausted rider is far more likely to make critical errors on the road.

Rain protection traps heat. Bulky design drains you. Loose pockets let armor shift. Do-it-all jackets fail at protection, comfort.

Finally, the traditional jacket design fails to keep vital impact protection exactly where it is needed during a crash. The loose shells allow armor pockets to shift, meaning protectors often rotate away from joints at the moment of impact. 

Why Layering Wins Every Time

The silver lining is that you don't need one expensive jacket to do three different jobs. At Bohn, we believe in a layering system that separates your impact protection, your abrasion layer, and your weather protection.

With this system, you wear a Bohn armored shirt as your first layer. This keeps your SAS-TEC CE-Level 2 armor snug against your skin. Because the shirt is made of Lycra™ and mesh, it is very comfortable and moves with your body.

Wear Bohn CE-Level 2 armor base, add any rain shell when needed. No expensive all-in-one jacket trying to do everything and failing.

When it starts to rain, you simply pull a lightweight waterproof shell over your gear. This shell can be a simple rain jacket that you keep in your saddlebag. Because it doesn't need to hold armor, the rain shell can be thin, packable, and very effective at blocking the wind and water.

Handling the Heat and the Rain

One of the biggest benefits of this system is how it handles changing weather. Imagine you are riding through the mountains. It is 85℉ in the valley, but as you climb, it starts to pour and the temperature drops to 60℉.

If you are wearing a heavy waterproof jacket, you are likely already sweaty from the valley heat. Now you are damp and the cold wind is hitting you. If you are using Bohn gear, you were cool and dry in the valley because our mesh shirts allow total airflow.

Valley heat? Cool. Mountain rain? Add shell. Sun returns? Remove it. Traditional jacket keeps you sweaty through every condition.

When the rain starts, you stop for a minute, put on your rain shell, and you are immediately warm and dry. The rain shell blocks the wind chill, and your Bohn shirt keeps your SAS-TEC armor in place. Once the sun comes back out, you tuck the rain shell away and you are back to being the coolest rider on the road.

The Importance of a Snug Fit

Typical motorcycle jackets have armor pockets that are often too big. If you have thin arms or a smaller frame, the elbow pads might slide down to your wrists. This is a major safety concern because the armor won't be there to mitigate impact damage if you go down.

Bohn gear is designed to fit like a second skin. We offer a huge size range from 3XS to 5XL, including Short, Tall, and Big sizes. We have helped riders from 4'9" to 6'10" find gear that actually fits their body shape.

Body-fitted armor stays in place, not loose pockets. Lycra holds 5×12" protection. 3XS-5XL fits riders 4'9" to 6'10". Second skin.

Our armored shirts use the stretch of Lycra™ to hold the pads in the perfect spot. Our elbow and forearm armor is a full 5 × 12 inches, giving you more coverage than almost any other brand. Because the fit is so good, you can wear your Bohn gear under a concealed carry jacket, a leather vest, or even a simple windbreaker.

High-Quality SAS-TEC Protection

We don't use cheap foam in our garments. Every piece of Bohn gear comes with SAS-TEC armor, which is a special material that stays soft until it is hit. This makes it much more comfortable for long days in the saddle compared to hard plastic protectors.

Our armor specifications are very specific to ensure the best coverage:

• Elbow and Forearm: 5 × 12 inches for long-reach protection.

• Knee and Shin: 5.25 × 12 inches to shield your lower legs.

• Shoulder: 5 × 8 inches for standard sizes, and 6 × 9 inches for our 3XL+ riders.

This armor has a lifespan of up to 10 years, meaning you won't have to replace it every couple of seasons. It is also CE-Level 2 rated, which means it has passed the highest testing standards for absorbing impact energy.

Frequently Asked Questions

Can I wear a Bohn shirt under a regular rain jacket?

Yes, that is exactly what we recommend. Because our armored shirts are so slim, they fit easily under most standard waterproof shells or rain jackets. This allows you to have top-tier impact protection without having to buy a dedicated motorcycle-specific rain jacket.

How do I know what size to get if I'm very tall?

We offer Tall sizes in our shirts and pants to make sure the armor reaches your joints correctly. If you are up to 6'10", we have gear that will fit you. Our 5 × 12 inch elbow armor is designed to cover the entire forearm of even the tallest riders.

Is SAS-TEC armor waterproof?

The SAS-TEC material itself does not absorb water and is very durable. However, we recommend removing the armor before you wash the fabric part of your Bohn gear. The fabric can be machine-washed on a gentle cycle, but the pads should be wiped down by hand if they get dirty.

What is the difference between CE-Level 1 and CE-Level 2?

CE-Level 2 armor is tested to absorb much more impact energy than Level 1. It is the higher standard and provides better protection for your bones and joints. All Bohn gear is designed to work with Level 2 SAS-TEC to give you the best possible safety.

Will the armor make me look bulky under a jacket?

Our goal is invisible protection. The Lycra™ fabric pulls the armor tight to your body, so it doesn't "pout" or stick out. Most people won't even notice you are wearing shoulder or elbow pads when you have a jacket over your Bohn shirt.

Does Bohn gear come with a warranty?

We stand behind our products because we have been building them for over 25 years. Our SAS-TEC armor is built to last for 10 years, and our fabrics are chosen for their durability and stretch. If you ever have a problem with the fit or quality, we are here in North Carolina to help you out.

Can I wear Bohn shorts under my rain pants?

Absolutely. Our armored shorts are a great way to add hip and tailbone protection if you are wearing waterproof over-pants that don't have their own armor. They are very thin and won't feel bulky in the seat of your motorcycle.

Is the gear hot to wear under a waterproof layer?

If you are wearing our Cool-Air or Airtex shirts, they are as breathable as gear can be. While any waterproof layer will trap some heat, the Bohn base layer helps wick sweat away from your skin. As soon as you take the waterproof layer off, the mesh allows the wind to cool you down instantly.