When the sun is high and the trails get technical, finding the right adventure gear for hot weather becomes a challenge for every rider.
At Bohn Body Armor, we have spent more than 25 years helping riders stay cool without giving up the impact protection they need.
We know how it feels to want to strip off heavy gear when the temperature climbs, so we built our systems to be the most lightweight and breathable options available.
If you choose the wrong gear for a summer ride, you run the risk of heat exhaustion which can lead to mistakes on the bike. There is nothing worse than being soaked in sweat and distracted by a heavy jacket when you are trying to navigate a tricky dirt section.
The relief of finding a setup that lets the air flow right to your skin while keeping your armor in place makes every mile more enjoyable.
We want to help you build a kit that works for your specific riding style and keeps you riding longer in the heat. This guide will show you how to layer correctly so you can stay safe while keeping as cool as possible.
Bohn helps riders beat the heat with lightweight, breathable armor systems and smart layering for cool, protected summer rides.
Top Recommendations for New Bohn Riders
Bohn Airtex Adventure Shirt
The Airtex Adventure shirt is our go-to choice for riders who want the most armor protection (including chest) with high airflow. This shirt is made from a mix of Lycra and mesh that lets every breeze reach your skin.
Inside the shirt, we have placed CE-Level 2 SAS-TEC armor at the shoulders, elbows, back, and chest (in either split or single piece of armor). It fits like a snug base layer, which means the SAS-TEC armor stays molded to your body and does not shift around if you happen to take a tumble.
Get the Airtex Adventure Shirt
Bohn Adventure Armored Pants
If you spend your time on technical trails wearing tall off-road boots, the Bohn Adventure Armored Pants are made for you. These pants use a breathable mesh fabric that wicks away sweat and keeps your legs cool in triple-digit heat.
They feature SAS-TEC armor at the hips, thighs, and tailbone, plus a special 5×8 SAS-TEC knee and shin protector that fits comfortably inside most adventure boots. They provide a layer of invisible protection that you can wear under your favorite riding pants or even a pair of light hiking pants.
Get Bohn All-Season Adventure Armored Pants
Bohn All-Season Armored Shorts
For those long rough rides when you want extra protection for your hips and tailbone without weighing yourself down, the All-Season Armored Shorts are a perfect addition.
These shorts are made with a soft Lycra™ mesh that feels like high-end athletic wear but holds rugged CE-Level 2 SAS-TEC armor. They are thin enough to disappear under your clothes, giving you peace of mind without adding any bulk or heat to your outfit.
Get Bohn All-Season Armored Shorts
3 Truths About Motorcycle Gear (That Might Surprise You)
Before we get into the technical details, I want to share three "controversial" truths about motorcycle safety. These principles drive everything we design at Bohn.
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Impact matters more than slide for overall safety - You have likely heard the old adage, "dress for the slide, not the ride." We believe that is incomplete, especially for adventure riders where crashes tend to be low speed over rocks and roots. Our priority is absorbing the energy of that first hard hit with SAS-TEC armor; we leave abrasion protection to secondary layers.
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Your expensive jacket might be failing you - Traditional motorcycle jackets – especially adventure jackets – often fit loosely to be comfortable. The problem? If the jacket is loose, the armor is loose. In a crash, that elbow pad can rotate around your arm before you even hit the ground. If the armor isn't between you and the ground, it's useless.
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Comfort supports safety. - If you are overheating, you are distracted. If your gear pinches or restricts movement, it can affect your focus and control. Bohn's breathable base layers help riders who skip wearing gear in heat actually keep their armor on. Being comfortable keeps your reaction times sharp.
The Problem with Traditional Adventure Gear
Most adventure gear is designed to look like it could survive a trip across a continent. While that looks great in photos, it often means the gear is made of thick, heavy materials that trap heat. Even if a jacket has vents, those vents only open a small part of the fabric. The rest of the jacket, including the pockets for the armor, acts like a heavy blanket.
In hot weather, this causes your body temperature to rise quickly. When you are riding a technical section of trail, you are moving your body a lot and working hard. You need gear that can breathe through every inch of the fabric, not just through a few zippered holes.
Bohn mesh base-layer armor lets air flow through every inch, keeping you cooler than even the best adventure jackets.
Bohn gear is designed to be a base layer. By putting the SAS-TEC armor in a mesh shirt or pant, we allow air to flow through the entire garment. This helps to wick sweat away and keep you dry.
You can then wear a very light, non-armored shell or jersey on top, which gives you more airflow than any traditional adventure jacket ever could.
Modular Gear for Changing Climates
One of the toughest things about adventure riding is that the weather can change in an instant. You might start in a hot valley and end the day on a cold mountain pass. If you are wearing a heavy, all-in-one jacket, you are stuck with that weight and heat all day long.
With a Bohn system, you have a modular kit. On the hottest part of the ride, you wear your Cool-Air Armored Shirt and a jersey. If it gets cold or starts to rain, you can just pull an insulated layer or a rain shell over your armor. This keeps you protected the whole time while allowing you to adjust your temperature easily.
Bohn’s modular armor system adapts to changing weather, letting riders layer up or down while staying protected on every ride.
If you are worried about sliding on the highway to get to the trail, we recommend wearing an abrasion-resistant outer layer over your Bohn armor. Once you hit the dirt and the speeds slow down, you can pack that heavy layer away. This flexibility is a big reason why adventure riders have trusted us since 1997.
Why Fit Matters for Your Safety
Safety gear only helps if it stays where it belongs during an impact. In many loose-fitting jackets, the elbow pads are much smaller than the area they need to protect. Our elbow and forearm SAS-TEC armor is 5 x 12 inches, providing coverage for nearly your entire outer forearm.
Because our shirts are made with a snug fit and stretchy fabric, that 5 x 12-inch piece stays right where it needs to be. It’s less likely to slide to the side or push up your arm when you hit the ground than the armor in a looser fitting traditional adventure jacket. This helps prevent injury to the bones and joints that are most likely to take a hit.
Snug-fitting SAS-TEC armor stays in place, covering elbows & forearms. Sizes 3XS–5XL, fits riders 4’9”–6’10” safely.
We also make sure our gear fits everyone. We offer sizes from 3XS to 5XL, and we include options for Tall, Short, and Big riders. Our gear is designed and sewn in the USA to fit riders from 4'9" to 6'10". Whether you are petite or very tall, the SAS-TEC armor will line up correctly with your shoulders, elbows, and knees.
The Durability of SAS-TEC Armor
We use SAS-TEC armor because it is the best material for the job. It is a viscoelastic foam that is soft and pliable when you are moving around. This makes it very comfortable to wear for long days in the saddle.
But when it takes a hit, it hardens instantly to mitigate impact damage.
Unlike some other types of protection, SAS-TEC armor can continue to perform after multiple crashes. This means if you have a small tip-over on a trail, you don't have to throw the armor away. As long as the armor itself isn't torn or cracked, it will keep working for you.
SAS-TEC armor is soft, comfy, and hardens on impact. Multi-crash compliant, lasts up to 10 years protection that endures.
The armor has a lifespan of up to 10 years, so it is a piece of gear that will stay with you through many different bikes and trips. This makes Bohn a very smart investment for any rider who wants to stay protected for the long haul.
Staying Cool on Technical Trails
When you are riding off-road, you are often moving at lower speeds. This means you don't have a lot of wind to help cool you down. In these situations, a traditional adventure suit can feel like a sweat-box.
Bohn's mesh fabrics are designed to allow even a slight breeze to reach your skin. This is especially helpful in high humidity, where sweat doesn't evaporate easily. The silver lining of technical riding is that while it is hot, the speeds are often lower, so the impact protection of Bohn gear is exactly what you need versus abrasion protection.
Bohn mesh gear keeps you cool off-road, even in high humidity. Soak in water for extra evaporative cooling on hot rides.
If you find that you are getting too hot, you can even soak your Bohn shirt in cool water before you put it on. The mesh will hold the water and provide evaporative cooling as you ride. This is a great trick for those desert days when the sun is relentless.
Frequently Asked Questions
Is Bohn armor as safe as traditional adventure jackets?
Bohn is designed to provide superior impact protection by keeping the SAS-TEC armor snug against your body. While it does not offer the same abrasion resistance as top adventure jackets, it mitigates impact damage much better than those jackets, which tend to fit more loosely. For the best of both worlds, you can wear an abrasion-resistant shell over your Bohn armor.
Will I look bulky wearing Bohn under my clothes?
No, Bohn is designed to be "invisible protection." The mesh and Lycra™ fabrics are very thin, and the SAS-TEC armor is shaped to follow the curves of your body. Most people won't even know you are wearing motorcycle gear.
What size should I order?
Our size range is very broad, from 3XS to 5XL. We recommend checking our size chart and choosing based on your height and weight. Since we fit riders from 4'9" to 6'10", we almost certainly have a size that will work for you.
Can I wear Bohn armor for street riding too?
Absolutely. Many of our customers use Bohn for their daily commute or weekend road trips. It is a great way to stay safe under regular clothes when you are riding around town.
How do I clean my Bohn gear?
Cleaning is easy. Just remove all the SAS-TEC armor pieces from the pockets and wash the fabric in your washing machine on a gentle cycle. Hang the fabric to dry, and it will be ready for your next ride.
Does the gear come with armor included?
Yes, all of our armored shirts, pants, and shorts come with a full set of CE-Level 2 SAS-TEC armor. The first time you purchase from us we recommend the full set of armor. Then you can purchase more fabric shells (without armor) as spares or to match different weather or bikes. We have three weights: Cool Air mesh, Airtex (Lycra/Mesh) and Performance Thermal (for cold rides).
How long does the armor last?
SAS-TEC armor is very durable and is designed to last up to 10 years. It can also handle multiple impacts, so you don't necessarily have to replace it after a small fall.
Where is Bohn Body Armor located?
We are headquartered in Mooresville, NC, which is just north of Charlotte. Our gear is designed and sewn in the USA, and we take great pride in the quality of every piece we ship.
