The HJC i91 Modular Helmet Review: Affordable, But Not Right For Me
Evan Rally
left for contents
The HJC i91 modular helmet is one of the most comfortable lids I’ve ever worn. It’s plush and well-padded, feeling like a helmet that costs twice as much. The modular chinbar, visor, shell and even sunvisor feel premium and make for a great touring helmet.
But despite the comfort and practicality it offers, I won’t wear this as my daily rider. Let me break down why this helmet is great in some aspects, and what I’d recommend instead.
But trust me on these:
- Comfort is unmatched: The HJC i91 liner is super comfortable (especially around the ears) and it’s a solidly-built helmet (aside from a few issues with the visor that I’ll get in to)
- The sunvisor is a sleeper hit: Unlike many subpar designs, the drop-down sunvisor here feels premium and is one of the few I’d actually use daily.
- Ventilation leaves something to be desired: If you’re riding in a hotter climate and need superb airflow, look into the i91’s upmarket cousin, the RPHA 91.
- Super comfortable liner and plush padding
- Polycarbonate shell
- 3 shell sizes for better fit, look, and weight
- Great drop down sun visor
- Heavy on the neck
Let’s get into what I like about this lid.
What I Like
The HJC i91 brings a lot to the table, especially for riders who prioritize comfort and practicality. While it’s not without its limitations, the features it gets right make it a strong contender in the modular helmet space for touring riders on a budget.
Modular Design: Practical and Versatile
You’re likely here because you want the convenience of a modular design helmet, the ability to flip up the chinbar for some fresh air at the gas station or a quick chat with your riding buddy.
For that the i91 does the job: the chin bar locks securely when closed – I haven’t had any issues with one or both sides of the locks not engaging. There’s a spring in the mechanism that pulls the chinbar up when you unlock it (from a button on the chin), and start flipping it up, and the detent at the top is strong enough to keep the chin bar up while you’re off the bike. It’s worth noting the chinbar doesn’t lock in the up position.
That said, this helmet is not designed to be ridden with the chin bar up. Safety tests are done with it down, and Sharp’s own independent safety testing of this helmet’s predecessor (the i90) indicate that the chin bar remains locked in 90% of impacts – meaning in 10% of tests, the chin bar came up and rendering any protection you had in the front null and void.
That might be just fine by you – just don’t think you’re buying the same protection you get in a fixed full-face helmet. If you’re looking for a helmet that seamlessly transitions between full-face and ¾ functionality, check out the HJC i100 or Shark Evo “transformer” helmets where the chinbar moves all the way to the back of the helmet.
Comfort: The HJC i91’s Best Feature
Comfort is where the i91 truly shines. The interior is plush and breathable, with plenty of space around the ears. On long rides, this extra breathing room makes a world of difference. It even edges out my Shoei RF-SR in terms of comfort—a surprising win for HJC in this category.
The eyewear channels are thoughtfully designed, ensuring glasses fit securely without pressing into your temples or disrupting the fit. The interior lining is not just soft but premium in feel, with moisture-wicking properties that keep you cool and dry.
The helmet’s neutral round oval shape was surprisingly accommodating, even though my head shape leans toward intermediate oval. While I do feel slight pressure on my forehead in this helmet, it’s not enough to cause discomfort, and the helmet’s overall fit remains snug and supportive through long rides.
This is even more surprising considering this helmet was purchased in Asia, and most helmet manufacturers (as I found out at Shoei’s Gallery store in Kyoto) create rounder EPS inners for the Asian market, with more elongated intermediate oval shapes for the Western market. For example, I couldn’t wear a Shoei RF-1400 in Japan, as even the Large size felt like it was hammering my forehead while I could slip a finger between the foam and the sides of my head.
One important sizing tip: don’t size up when buying a modular helmet. Many touring riders tend to do this for more comfort, but you’re doing yourself a disservice when it comes to safety. You want a modular to fit just the same as a full face: nice and snug, with chipmunk cheeks when new. Trust me that padding will break in over time. Check out our Helmet Fit and Sizing Guide for a checklist on how to fit a motorcycle helmet properly.
Visors: Mixed Bag
I’ll start with the good.
The drop-down sunvisor on the HJC i91 is the best one I’ve ever seen on a motorcycle helmet.
Usually these are flimsy, distorted, and generally annoying to use and see through in just about every way. I hate them! Many sunvisors on modular touring helmets feel like an afterthought, but not here.
The sunvisor in the i91 might be the first one I ever use, since it is executed with precision. Tight margins at the bottom mean no distracting seams visible while riding, and it’s free of any distortion. HJC also gives you some adjustability; the height that the visor drops to can be fine-tuned via a control panel on the left side of the helmet, allowing you to customize the visor’s position for optimal coverage depending on the light conditions or where your eyes sit in the helmet. This level of functionality is rare and makes the visor genuinely practical—a feature I’d happily use on a daily basis.
Then there’s the standard clear visor – which gets the job done, but definitely starts to show the budget price range this lid sits in.
The visor locks down firmly with a small tab in the center, and the helmet is packaged with a Pinlock visor. However, that’s where the good ends with this visor.
And that brings me to what I don’t like about this lid…
What I Don’t Like
While the HJC i91 gets a lot right, there are a few areas where it misses the mark. Some are minor annoyances, but others are more significant, especially for riders who demand top-tier performance.
Cheap Visor
My main gripe with the visor on the i91 is it’s made of thin material making it susceptible to flexing in the wind and letting noise into the helmet. The rubber around the visor also doesn’t seal well – it’s not particularly thick, and the visor doesn’t have any mechanism pulling it tight to the seal.
And the detents on the visor are too shallow, making it difficult to leave the visor cracked open for airflow. This can be especially irritating in hot or humid conditions where a bit of extra airflow is essential.
Maybe I’m just spoiled by the visor, detents, and seal on my Shoei RF-SR, but the cheapness in this area just degrades the overall experience in the helmet – especially noticeable on long tours with a lot of wind noise.
The visor’s issues likely contribute to the next downside: noise.
Noisy – even for a Modular
Noise is a common trade-off with modular helmets, but the i91 is particularly loud, even compared to other modulars. It’s significantly noisier than the Schuberth C3 I’ve done some touring in on my old Harley, which surprised me given the amount of padding in the i91.
I suspect the visor’s less-than-perfect seal plays a role here, allowing wind noise to creep in. For long highway rides, the added noise is fatiguing, even with earplugs.
Ventilation (or Lack Thereof)
It certainly isn’t an abundance of ventilation causing all that noise in the i91 – given this lid only has a large chin vent and one single top vent. In my experience riding in this helmet, that means not much airflow around the forehead. Fine if you’re riding in colder weather, but something to keep in mind for sweltering summer days.
Thankfully HJC solves this with their upmarket RPHA 91, which I’ll get to later.
Communicator Compatibility
The HJC i91 is compatible with Bluetooth communicators, but not without some hiccups. While it fits its own custom made “Smart HJC” communicator from Sena (based on the Sena 20S) very well, I had trouble installing a Cardo Spirit HD unit. The speakers fit into the helmet’s pockets, but positioning the boom mic proved challenging due to the tightness of the cheek pads against the shell. They really designed this helmet only for that specialized Smart HJC unit.
For riders who rely heavily on their communicators for navigation, calls, or group rides, this added hassle could be frustrating. If you’re using a standalone unit, especially one with a boom mic, expect to spend extra time adjusting it to fit securely—or consider alternative helmets with more universal communicator integration.
Weight: A Heavy Contender
At over 4 pounds, the i91 is on the heavier side even for a modular helmet. The model I tested, equipped with a Cardo unit, tipped the scales at 4 lbs 3 oz, and you can definitely feel the extra weight during extended rides. For comparison, my Shoei RF-SR comes in at just 3 lbs 10 oz (with a weighty Cardo Edge unit installed) —a significant difference that affects comfort and neck fatigue.
This weight is the second biggest reason I won’t wear this as my daily helmet: the main issue is its polycarbonate shell.
Shell Materials and Safety
What you lose in price with a polycarbonate helmet shell like the i91 has, you also lose in safety.
Polycarbonate falls short in impact dispersion compared to more advanced materials like composite fiberglass and carbon fiber. Sharp testing on its predecessor, the i90, revealed poor performance in the temple area during higher-speed impacts. While the i91 hasn’t been tested yet, the i90 has that same polycarbonate shell.
Thankfully HJC offers another option with the same modular chinbar and even better fit and finish (including brow vents): The HJC RPHA 91, which features a composite PIM shell with far superior impact protection.
Comparisons
The HJC i91 sits in an interesting spot in the modular helmet market, offering a mix of comfort and practicality at a value-driven price point. However, when compared to its competition, its strengths and limitations become more evident – especially when it comes to safety.
VS Shoei RF-SR
Now I know the RF-SR is a full-face, so this isn’t an apples to apples comparison. However, I have tens of thousands of miles in this Shoei so it has set my benchmarks for evaluating helmets. The RF-SR is also a great sport touring helmet, which is a category the The Shoei RF-SR, a full-face helmet, represents the gold standard for fit and finish, especially for riders who prioritize quietness and aerodynamic efficiency.
- Fit and Seal: The RF-SR excels with its snug, consistent fit around the crown and a visor seal that leaves no room for wind or moisture. In comparison, the i91 offers great comfort around the ears but sacrifices the crown’s solid, locked-in feel.
- Noise Reduction: Shoei’s focus on quietness makes the RF-SR far superior for long-distance rides. In contrast, the i91, like many modulars, struggles with wind noise, amplified by its less-than-perfect visor seal.
- Shell Safety: The RF-SR has a composite shell, and you pay for that privilege. That said, the RF-SR (Ryd in Europe) scored 5/5 on SHARP’s testing criteria whereas the i90 (and presumably i91) only scored 3/5.
- Comfort Comparison: Where the i91 wins is in ear comfort and plushness, which is better suited for riders with a neutral or slightly round head shape. However, the RF-SR provides a more universally solid fit, appealing to those seeking all-around support and performance.
Read my full review on the Shoei RF-SR here.
- Sturdy build quality from the padding to the visor
- Composite AIM shell (not plastic / polycarbonate)
- Comfortable and snug liner
- Durable (I've battered the poor thing)
- Affordable 💵
VS HJC i100
For riders wanting a true dual-purpose helmet—one that functions seamlessly as both a full-face and a 3/4 helmet—the HJC i100 is worth exploring (along with the Shark Evo line).
- More Modular Functionality: While the i91’s modular design works well for short breaks and convenience, the i100 is specifically engineered for full-time 3/4 and full-face versatility. The chin bar on the i100 rotates entirely to the back of the helmet, creating a more balanced and functional 3/4 configuration.
- Who It’s For: If you frequently switch between open and closed configurations while riding, the i100 is the better choice. However, if you’re mainly riding full-face with the occasional flip-up, the i91 is a more budget-friendly option.
- Advanced Polycarbonate Composite Shell
- Advanced Channeling Ventilation System
- Pinlock ready HJ-36 face shield
- Quick and secure shield ratchet system
- Double D-Ring chinstrap
VS HJC RPHA 91
The i91 and the RPHA 91 are siblings in the HJC lineup, but they cater to different riders. The RPHA 91 is a premium modular helmet designed for those seeking top-tier protection and refined features. With the same robocop look you’ve come to expect from a touring modular.
- Shell Material: The most significant difference is the shell material. The RPHA 91 uses a composite PIM shell, which offers vastly superior impact protection, especially in the vulnerable temple area. In contrast, the i91’s polycarbonate shell is functional but less effective in impacts.
- Ventilation and Comfort: With vents added at the brow, the RPHA 91 features improved ventilation and enhanced airflow, making it better suited for warmer climates and longer rides.
With a higher SHARP rating and better impact safety, particularly on the sides of the head, the RPHA 91 is the helmet of choice for riders who prioritize safety and are willing to pay extra for it. For those on a tighter budget, the i91 delivers many of the RPHA’s comforts at a fraction of the price.
- Quick, Simple and Secure Visor Ratchet System
- Adjustable 3-step sunshield (HJ-V12) for optimized position
- Dark Smoke Sunshield Installed
- Removable/washable crown and cheek pads
- Ready for 21B & 50B Bluetooth (sold separately)
HJC i91: The Right Helmet for You?
The HJC i91 modular helmet is an excellent choice for riders seeking comfort and functionality without breaking the bank. At around $250, it offers a plush interior, a reliable modular design, and features like a standout sunvisor that rival more expensive helmets. However, it does come with trade-offs, particularly in terms of noise reduction, ventilation, and safety compared to premium models like the HJC RPHA 91 or Shoei RF-SR.
If you’re a touring rider or commuter looking for a well-rounded, budget-friendly helmet, the i91 delivers great value. But for those prioritizing safety, quieter performance, or enhanced airflow, exploring higher-end options may be worth the investment.
Ready to upgrade your gear? If the HJC i91 sounds like the right fit for your rides, check out the latest prices and availability through the links below. If you’re able to spend a bit more, go for the RPHA 91.
- Super comfortable liner and plush padding
- Polycarbonate shell
- 3 shell sizes for better fit, look, and weight
- Great drop down sun visor
- Heavy on the neck