HJC i91 Manual

Features

	Advanced Polycarbonate shell		Interchangeable cheek pads throughout all sizes
	Advanced Channeling Ventilation System		New Micro buckle
	Pinlock ready HJ-33 visor(shield)		ECE R22.06 APPROVED
	Provides 99% UV protection		P/J APPROVED
	Removable and washable interior		Smart HJC 21B & 50B Install ready
	HJ-V12 Internal sunshield

Selecting the Right Size

Never buy a used helmet or borrow someone else's helmet. Over time the protective foam in helmets will adjust to the contours of a user's head. A used or borrowed helmet may not offer as much protection as a new helmet.

Wearing the wrong size helmet can increase your risk of serious injury or death in an accident. A helmet that is too large for your head may be dislodged or knocked off in an accident. To select the right size helmet for your head, follow these instruction:

1. Measure your head. Wrap a tape measure around your head about one inch (2.5cm) above your eyebrows.
2. Use the sizing chart to select the helmet size that corresponds most closely to your head measurement. If your head size falls between two helmet sizes, try on the larger helmet first and then the smaller size.

Size Chart

The size chart is only for reference. Always try the helmet on and follow this manual's instructions for a proper fit.

3. Try on the helmet by grasping both chin straps to pull the helmet completely onto your head, ensuring that the top of your head is in contact with the top of the helmet interior.
4. Check for a proper fit. To make sure your helmet is the right size, check that:
   • The helmet inner lining fits snugly around your head.
   • The top pad presses firmly on your head.
   • The cheek pads contact your cheeks.
   • There is no space around your brow under the inner lining. Test this by trying to insert your fingers.

If the helmet does not fit snugly, try on a smaller size.

5. Check your field of vision when trying on a helmet. Some helmets may obstruct or block your vision when looking left, right, up, or down.

Always make sure you can see well enough to safely operate your motorcycle.

6. Test the helmet fit by placing your hands on each side of the helmet. While holding your head as motionless as possible, try rotating your helmet from left to right then up and down. If you can feel the helmet padding sliding on your head, it is too big, try a size smaller. You should feel the helmet move the skin on your head and face as you try to move the helmet.
   
7. Fasten the retention system (chin strap) as tight as possible under your jaw without causing pain. There must be no slack in the strap, and the strap must be tight up against your jaw. See "Fasten the Retention System".
8. Test the retention system (chin strap)
   • Put your hands on the back of the helmet and try to push the helmet off by rotating it forward.
     
   • Put your hands on the front of the helmet above your forehead (or on the chin guard) and try to push the helmet off by rotating backward.

If helmet comes off or shifts over your eyes, try another size or another model or brand. You must be able to see the edge in your upper field of vision.

Repeat steps 3 throught 8 until you find a helmet that fits your head snugly and securely.

Specifications

1. Outer Shell
2. Rear Venturi Exhausts
3. Shell gasket
4. Bluetooth Cover
5. Sun Shield Lever
6. Chin Strap
7. Micro Buckle
8. Bluetooth UI Cover
9. Modular Chin Bar
10. Chin Bar Lever
11. Lower Vent
12. Breath deflector
13. Pinlock Pins
14. HJ-V12 Sun shield
15. HJ-33 Visor(Shield)
16. Eyeport Gasket
17. Visor(Shield) Ratchet
18. Top Vent

Using Your Product Correctly

To reduce the risk of serious injury or death and to help prevent damage to your helmet:

• Never adjust your helmet accessories while riding - Only make helmet adjustments when stopped.
• Never drop your helmet - Dropping your helmet may crack the shell or damage the protective foam. The damage may not be visible. Your helmet is only designed for ONE impact. Refer to "Product Replacement" for more information on what to do after helmet has been dropped.
• Never wear anything between your head and your helmet – this may reduce the effectiveness of your helmet.
• Never hang or hook your helmet on anything including mirror stalks or sissy bars - Doing so may cause damage to the helmet protective foam or liner.
• Never use insect repellent on or around your helmet – insect repellant may damage your helmet's visor(shield), shell, protective foam, or other components.
• Never expose helmet to gasoline or gasoline fumes – Gasoline may damage your helmet's visor(shield), shell, protective foam, or other components.
• Never use a dark or tinted face visor(shield) at night or in low visibility conditions. - If you have any questions on what other substances may damage your helmet, please contact us.
• Always wear eye protection - If you are not using a helmet with a face visor(shield), always wear eye protection when riding. Always lock your face visor(shield) in place when you are riding.
• Always be alert for sounds - Your helmet may impair your hearing. However, your helmet is not a form of hearing protection.
• Always store your helmet in its helmet bag when not in use to help reduce accidental surface damage.

To reduce the risk of serious injury or death, always use your helmet correctly.

Inspect your product

To ensure that your helmet is in the best condition to maximize your protection, always inspect your helmet for damage before riding:

• Check the visor(shield) and visor(shield) ratchet – re-tighten visor(shield) ratchet screws if necessary. Be sure not to over tighten any screws. Plastic base plate screws can break and plastic screws can strip the screw sleeves if over-tightened.
• Check for helmet damage. If your helmet is damaged or cracked, stop using it immediately. See "Product Replacement" section for further information. If your helmet has been dropped, you may not be able to see the damage.
• Check for worn or damaged parts. Plastic components may wear out over time. If you find worn or damaged parts, replace them or purchase a new helmet. See "Replacement Parts" for information on parts replacement.

If parts fall off while riding, your vision may be blocked which could cause an accident.

• Check the retention system (chin strap) for damage. If it is frayed or ripped, replace the helmet.
• Check that all pads are in place. Both of the cheek pads and the crown pads must be in place.

Check Your Face Visor

If your face visor(shield) is scratched or damaged it may reduce the visibility-replace if necessary. Always make sure you can see well enough to safely operate your motorcycle.

Fasten the Retention System

Fasten the retention system (chin strap) as tight as possible under your jaw without causing pain. There must be no slack in the strap, and the strap must be snug up against your jaw. If the retention system is not tight, your helmet may become dislodged or knocked off in an accident.

Micro Buckle

Hold the clip and pull the chin strap as directed above to adjust the fit.

Maintaining Your Product Correctly

Shell Cleaning

Do not apply paint, stickers, petrol, or other solvents to this helmet.

Only use approved methods to clean the helmet. Using other unapproved chemicals or methods may damage the helmet shell or lining. A damaged helmet may increase your risk of serious injury or death in an accident.

Glossy Finish. HJC recommends cleaning your helmet with products designed for automotive cleaning and polishing. All HJC helmets are finished with an automotive type base coat/clear coat finish. Rubbing compounds can be used for deep cleaning to remove many scratches and scuffs. Follow the product's instructions diligently. Over polishing with rubbing compounds can cause light abrasions which may dull the finish of your helmet. Stickers and decals will leave adhesive residue when removed. To remove the adhesive residue, use alcohol swabs. Be certain to immediately wipe away the excess liquid and clean the area with soap and water once the adhesive residue is removed. Do not use excessive pressure while rubbing when attempting to remove the adhesive residue, instead use multiple light treatments.

Non-Glossy Finish. For our flat finish (non-glossy) helmets, we recommend using warm water and mild soap. Use multiple treatments for heavier dirt. Do not use excessive pressure or rubbing compounds while cleaning the surface as a "glossy" effect could be created, running the flat finish appearance.

1. Please clean helmets from dust, bugs or grass within one day.
   • Cleaning progress
     1. Clean the helmet with warm water and cloth.
     2. If there are any remains left, dry the helmet and remove any remaining contamination with rubber eraser.
        *Do not use any alcohol or thinner to clean the helmet because they may damage the paint.
2. Avoid oil contamination as it is extremely difficult to clean once exposed.

Interior Cleaning

Although we recommend changing a helmet every 3 to 5 years, the accumulation of sweat, humidity and dirt can deteriorate the fabric and stitching and this may cause odor. To wash HJC removable pads, hand washing is recommended. If you use a washing machine, please use on "Delicate" setting and air dry. HJC do not recommend using spin-dryer for the interior pads as it may damage the material. For non-removable interiors, HJC recommends using anti-bacteria and mildew eliminating products such as "Helmet Fresh." or other similar product.

Vent Cleaning

Dirt and debris can find its way into venting of your HJC helmet. Compressed air cans used for cleaning computer keyboards may be used to blow the debris from the ventilation system. It is recommended that you remove any removable pads before doing this process.

Visor Cleaning

The helmet visor(shield) is made of polycarbonate materials with a polyurethane abrasion resistance coating. It should be cleaned using mild soap and warm water. Never use hot water, salt water, benzene, thinner, gasoline or any other harsh agents. Additionally the use of commercial visor(shield) cleaners is not recommended because they may affect the quality of the visor(shield) material. Treat carefully when cleaning the visor(shield) to preserve the abrasion resistant coating. When deep scratches are visible, it is highly recommended that the helmet visor(shield) be replaced. Tinted visor(shield) are for "Day time use only" and are not suitable for use at night or in conditions of poor visibility.

Visor Removal

1. Open visor(shield) to the maximum open position.
   
2. Pull the ratchet handle to the open position, then pull out the visor(shield) from ratchet mechanism.
   

Visor Installation

1. Align and insert the top of the visor(shield) guide into the ratchet guide.
   
2. With the guides properly aligned, press the lower section of the visor(shield) into the ratchet mechanism. The locking tab should pop into position, locking the visor(shield) into place.
   

Always check to make sure helmet pads are installed before using the helmet. A helmet with missing or improperly installed pads may increase your risk of serious injury or death in an accident.

Cheek Pad Removal

There are 3 snaps holding the cheek pad in place.

1. Gently pry the check pad away from the interior, releasing the snaps.
   
2. Grasp the cheek pad near its center and gently pull it free from the chin strap.
   

Cheek Pad Installation

1. Feed the chin strap through the opening in the cheek pad.
   
2. Align and fully slide the cheek pad plastic plate between shell and Liner.
   *Slide tab 'A' from the cheek pad into the holder 'B'. (Repeat same on opposite side)
   
3. Clip the cheek pad's 3 small male snaps to the 3 female snaps fixed on the shell interior.
   

Comfort Liner Removal

1. Grasp the comfort liner fabric as close as possible to its plastic base and pull/pry away from the helmet. Notice how the comfort liner plastic section aligns with the shell plastic sleeve. This will help orient you with the reinstallation.
   
2. Repeat same at rear.
   

Comfort Liner Installation

1. Install the front section first by aligning the plastic shell base and the comfort liner plastic sleeve, ensuring that the center and side holes are properly aligned. Press the comfort liner plastic sleeve (center portion) into the center of the channel which is built into the plasticshell base, working your way outward to each side.
   
2. Align and snap the two rear snaps into place.
   

Try not to operate the sun shield while riding as this may impair your vision and may lead to an accident.
DO NOT pull on the sun shield when it is already down. The sun shield may be ejected and this will increase the risk of serious injury or death in the event of an accident.
DO NOT attempt to adjust the sun shield itself with your hands. Always use the sun shield lever.
DO NOT use sun shield at night time. The sun shield is only for day time use. The sun shield does not provide eye protection. When you use the sun shield be sure that the clear visor(shield) is also in closed position.

Sun shield Operation

Above illustration shows raised sun shield position.

Above illustration shows lowered sun shield position.

There are three positions for the sun shield sliding lever.
Stage 1 - Standard position
Stage 2 - Higher position
Stage 3 - Highest position

Sun shield Removal

1. Place the stopper in stage 1.
   
2. Push the sun shield lever in the direction of the arrow to lower the sun shield as much as possible.
   
3. Gently pull one side of the sun shield as arrow indicates. (Repeat same for other side)
   

Sun shield Installation

1. Insert sun shield tab 'A' into 'B' position.(Repeat same on opposite side)
   *When installing the sun shield, be sure to have it slided behind the tap 'B' holder.
   

Breath Deflector Removal

1. To remove the breath deflector, pull in the direction of the arrow.
   

Breath Deflector Installation

1. To attach the Breath Deflector, insert into the slot and push it in the direction of the arrow.
   

How to install additional Chin Curtain

*This pad is attached in the interior of chin curtain and it blocks the air coming in towards the neck.

HJC Intercom Placement Guide

Mounting the Intercom
Unscrew and remove the base cover at the back of the helmet to begin mounting process of the intercom. Please refer to the manual of the current intercom you are using for directions on mounting and unmounting the intercom unit.

Base Cover Detachment

1. Remove the screws from the base cover. (picture1)
   
2. While lifting the base cover(direction A) detach it by pushing toward direction B. (Picture 2)
   

Mounting the Base Cover
Push the base cover underneath the gasket at the bottom of the helmet until the base cover and the bracket screw holes match. Using the screw, fixate the base cover onto the helmet.

Bluetooth UI Cover Detachment

1. Push the Bluetooth UI cover in the direction of the arrow while pressing down on A.
   

Mounting the Bluetooth UI Cover

1. After aligning the hook of the Bluetooth UI cover with the groove of the body, and push and attach.
   

• When using the intercom, depending on the sound settings of the intercom or connected device, surrounding sounds may be muted. When using, set the settings so that the surrounding sounds may be heard.
• If the intercom is mounted onto the helmet, please be aware to not misplace/lose the detached base cover and screws.
• If forcefully taking apart the bracket from the helmet, there is a risk of damage to the helmet.
• For the intercom, only use the specially designed products that is recommended by HJC.
  For information regarding the recommended products, please refer to the HJC official website.
  (https://www.hjchelmets.com)
• Before using the intercom, please make sure to read the instruction manual of the intercom currently in use. Also refer to the instruction manual of the intercom currently in use for instructions on how to handle the intercom itself.
• When mounting the intercom, all devices (including the mic and speaker) must be tested to ensure that they are in the best possible location. If it is determined that the mounted intercom would be a hindrance to riding, do not mount and contact your nearest HJC Dealer.

Opening Chin Bar

1. To open the chin bar, simply pull the lever forward and push the entire bar upward.
   
2. The chin bar is in the full open position when you hear " click" sound.
   

To maximize helmet's ability to protect, we highly recommend to ride with the chin bar in closed position. In the event a rider rides with the chin bar open, there is an increased risk of injury to the frontal area. Do not raise or lower the chin bar while riding. This may interrupt rider's ability to control the motorcycle and may lead to an accident. Please use care when opening or closing the chin bar as it may scratch the helmet. Damage caused by this is not subject to manufacturer's warranty.

Closing Chin Bar

When the visor(shield) is open and the chin bar is raised and lowered to a lock position, the visor(shield) may not be in a latched position with the chin bar. Before riding, please make sure that the shield is latched with the chin bar securely.(Center closure system)

Pull the chin bar downward to completely cover your face and chin. Listen for "click" sound to ensure that the chin bar has locked into its full closed position.

Replacement Parts

Always check to make sure helmet pads are installed before using the helmet. A helmet with missing or improperly installed pads may increase your risk of serious injury or death in an accident.

Do Not Modify Your Helmet
Your HJC helmet is designed to meet ECE R22.06 standard. Contact HJC Europe for more information about the ECE R22.06 standard. Modifying your helmet may increase your risk of serious injury or death in an accident. Do not modify your HJC helmet. Modifications include the following:

• drilling holes;
• cutting shell, liner, or strap;
• modifying the retention system, including adding a chin cup;
• removing parts;
• painting; and
• attaching accessories that are not manufactured by HJC for this helmet.

If you have questions about modifications, please contact HJC, See back cover for contact information.

Storing Your Product and Visor Correctly

An improperly stored helmet and visor(shield) can become damaged and may increase you risk of serious injury or death in an accident. You should:

• Store helmet and visor(shield) in a cool and dry place,
• Keep helmet and visor(shield) away from pets and other animals,
• Keep helmet and visor(shield) away from heat in excess of 50°C and do not set on or near hot surfaces.
• When helmets left out in the sun for extended periods of time, it may fade overtime.

Product Replacement

Although your HJC helmet is constructed with the best materials available to offer a long-lasting product, it will eventually need to be replaced. Immediately replace your helmet if:

• It has suffered an impact. Your helmet is only designed for ONE impact. An impact may fracture the outer shell or compress the impact absorbing liner. You may not be able to detect this damage. Any impact in a crash or a drop from as low as 4 feet is enough to damage your helmet.
• The shell, lining, or retention system is damaged. The helmet shell, the impact absorbing lining, and the retention system must be in good condition to provide you with the most protection.

Even if your helmet has not been damaged, it needs to be replaced every 3 to 5 years depending on how much you use it. Over time, UV rays and adhesive and component aging will damage your helmet. Wearing a damaged helmet may increase your risk of serious injury or death in an accident. If you are unsure if you need to replace your helmet, contact HJC Europe before using your helmet again.

Important Safety Information

The instructions in this manual are designed to help you select the right helmet, wear it properly, take care of it, and know when to replace it. Failure to follow these instruction may increase your risk of serious injury or death in an accident. In order to get the most protection possible from your helmet, you should always do the following:

• Wear your helmet when you ride;
• Handle your helmet carefully to avoid accidental damage; and
• Ride safely – do not take risks because you are wearing a helmet.

Although your HJC helmet is designed to reduce or prevent some injuries when worn, no helmet can protect you from all possible or foreseeable impacts. For example, your helmet cannot protect you from spinal or neck injuries. In addition, there is no guarantee that your helmet will PREVENT injuries to the area of your head that is covered. A low speed accident may even result in serious injury or death.

Please visit www.hjchelmets.com for more information about HJC helmets.

Documents / Resources

References

• HJC Helmets Official Site – Full-Face, Open-Face, Off-Road Motorcycle Helmets
• HJC Helmets Official Site – Full-Face, Open-Face, Off-Road Motorcycle Helmets

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