509 Forge Insulated Jacket Review: Does It Keep Riders Warm in Frigid Weather?

Riding a motorcycle in freezing temperatures can be miserable if you don’t have the right protective gear. But does the 509 Forge Insulated jacket really provide enough warmth for bitter-cold winter riding?

In this 509 Forge Insulated Jacket review, we’ll compare the 509 Forge Insulated jacket to similar competing products to help you decide if it’s the ideal choice for your cold-weather adventures.

We’ll explore the insulation, weather protection, features, sizing, and real rider reviews to shed light on how well this jacket performs when the mercury plummets.

But, the main question I will answer in this review will be: Is this the best motorcycle jackets for the winter for you? Let’s find out!

509 Forge Insulated Jacket Review


Key Takeaways

  • Primaloft insulation blocks wind chill
  • Heavy-duty shell resists tearing
  • Condensation builds up inside the jacket

More Key Takeaways: 509 Forge Insulated Jacket

A Heavy-Duty Insulated Shell for Frigid Rides

The 509 Forge Insulated motorcycle jacket (1Opens in a new tab.)features Primaloft Gold Insulation, which is rated for temperatures as low as 14°F/-10°C.

With a completely waterproof and breathable outer shell made from 500D Cordura Ripstop Polyester, this jacket aims to keep riders comfortable in the harshest conditions.

The Forge Insulated jacket uses Primaloft Gold Insulation, a high-quality synthetic fill that provides excellent warmth while allowing moist air and sweat to pass through.

This advanced insulation retains heat even when wet, making it ideal for snowy and icy rides where getting soaked is a risk.

According to 509, the 100g insulation is calibrated to keep riders cozy in temperatures ranging from 30-14°F when worn with proper base and mid layers.

For even colder expeditions or stationary activities, the jacket can be combined with extra insulation underneath or heated gear to block icy winds.

The outer shell utilizes 500D Cordura Ripstop Polyester, an extremely rugged and abrasion-resistant material originally developed for military use.

This heavy-duty fabric stands up to the hazards encountered off-road while resisting tears and scuffs during crashes and spills.

The Forge Insulated jacket is also guaranteed fully waterproof thanks to taped seams and waterproof zippers throughout.

The material provides excellent precipitation protection while allowing interior moisture to vent through the breathable membrane.

Engineered to Endure All Weather Extremes

In addition to advanced insulation and waterproofing, the 509 Forge offers numerous features to optimize comfort across a wide range of conditions:

  • Removable CE armor at the elbows, shoulders, and back provides impact absorption for unforeseen falls. Riders can add a spine protector for extra defense against trauma.
  • Ventilation zippers allow you to fine-tune airflow across the front torso and back panel as you heat up or cool down.
  • The inner insulated liner can be removed on warmer yet still chilly days to create a lighter shell layer.
  • Reflective logos and trim surround the jacket to make you visible at night.
  • Adjustable wrist closures and waist tabs let you seal out wind or relax the fit as needed. The jacket is cut longer at the back to prevent air infiltration when leaned forward.
  • A neck brace-compatible design ensures full coverage and overlaps when riding with extra protection.

With capabilities optimized for everything from sunny trail rides in the 30s to blizzard-like freeway commutes below zero, the 509 Forge Insulated jacket is equipped for the full spectrum of cold weather motorcycling challenges.

Sizing Runs Large. Check Measurements Carefully

The Forge Insulated jacket uses a relaxed fit cut designed to wear over protective gear or extra layers. Most riders recommend ordering a size down from your normal jacket size if you plan to wear the Forge as an outer shell.

The sleeves are especially generous, designed to overlap over the wrist while in a riding position. Riders with slender arms may need to tighten the velcro adjuster to prevent air from sneaking in.

Consult the 509 size chart and measure your chest circumference over your existing gear to choose the best fit.

If you fall between sizes, consider sizing down for a closer fit or sticking with your larger measured size if you prefer room to add layers underneath.

Also, note that the jacket fits differently when the insulated liner is removed. Trying it on both ways can help you find your ideal configuration.

509 Forge Insulated Jacket Sizing Chart


Excellent Warmth, But Condensation is a Concern

Overall, most riders are impressed with the Forge Insulated jacket’s thermal protection in frigid temperatures.

The Primaloft insulation blocks wind and locks in body heat even when soaked. The outer material also resists snow and moisture infiltration far better than standard textile jackets.

However, the mega waterproof design does lead to internal condensation issues for some users. The sealed seams and interior membrane prevent exterior water from seeping in, but they also greatly restrict interior moisture from evaporating out.

Several reviewers mention getting wet from the inside out due to body sweat accumulating within the jacket. In very cold and humid conditions, managing condensation can be difficult.

Utilizing the vents or removing the insulated liner may help increase airflow and reduce interior dampness issues.

Other Insulated Jackets to Consider

The 509 Forge Insulated jacket is at the high end for warmth, waterproofing, and off-road protection. But riders looking for more street-focused features or different insulation technology may prefer alternative options like:

  • Alpinestars Valparaiso Drystar – Uses a thinner Primaloft liner for better airflow and less sweat buildup during high-exertion riding. Also, cut shorter for street bike ergonomics.
  • REV’IT! Cayenne Pro – Insulated with down feathers for lighter weight and compressibility compared to synthetic fill. Features a removable thermal vest liner and rain shell.
  • RXR Dryft Insulated – Utilizes 3M Thinsulate filling, which provides ample warmth with increased breathability and quicker drying compared to standard insulation.

While these options from Alpinestars, REV’IT!, and RXR offer compelling features, the 509 Forge still reigns supreme for hardcore cold weather and off-road use.

The robust outer material and full membrane