1960

The ultimate leather suit made its debut in 1955 at Asama

KUSHITANI began crafting one-piece leather suits in 1953, commissioned by Suzuki. At that time, there were no leather suits available in Japan, so the initial designs were made by mimicking foreign catalogs. The first version simply combined a leather jacket and riding pants into a single piece, using soft, supple calfskin leather.

In an era when Japan lacked fully paved circuits, road races were held at military airfields like Gan-no-Su in Kyushu, and road racing itself was virtually non-existent. After much trial and error, the one-piece leather suit was finally put to the test at the Asama Highland Race in November 1955 (the first All Japan Endurance Road Race), where it proved its worth. Riders such as Richi Ito, Toshio Kamiya, and Rinsaku Yamashita wore the suits and received high praise.

Following this, Japanese manufacturers, starting with Honda, began to participate in events like the Isle of Man Tourist Trophy  Race and the World GP. Naturally, KUSHITANI's leather suits evolved from their Asama origins to fit the body better and look more streamlined. In 1962, KUSHITANI suits made their debut at the Isle of Man TT, worn by Suzuki's Ernst Degner (who won the GP50) and Mitsuo Ito (who finished fifth in the same class). The following year, in 1963, Mitsuo Ito became the first Japanese rider to win at the Isle of Man TT (GP50), also wearing KUSHITANI gear.

In September 1962, Japan's first fully paved racing circuit, Suzuka Circuit, was completed. By 1963, the World GP was held, marking the dawn of Japanese road racing.

Hard Knee Cups Marks a Significant Evolution in Protection

As the 1970s dawned, GP riders began to transition from the traditional monochrome leather suits to vibrant, eye-catching designs, embracing a newfound expressiveness on the track. This evolution allowed riders to personalize their gear, showcasing their names and team logos with pride. While many continued to appreciate the luxurious softness of calfskin, cowhide rapidly became the material of choice, renowned for its superior tear resistance and durability. The most significant advancement during this era was in rider protection. As motorcycles reached unprecedented speeds and tire grip improved dramatically, riders leaned deeper into corners, often resulting in harsh impacts during falls. In response, suits began incorporating hard plastic knee protectors, meticulously engineered to absorb impact and enhance safety. Influenced by the groundbreaking techniques of riders like Jarno Saarinen, who popularized the dynamic hang-off riding style, American racers began to intentionally press their knees to the ground, prompting further innovation in leather suit design. In the absence of dedicated knee sliders, many riders exhibited remarkable ingenuity, reinforcing their suits with layers of thick tape or sewing additional leather patches over vulnerable areas. Some even affixed robust leather typically used for shoe soles, ensuring enhanced durability. The silhouette of the suits underwent a sophisticated transformation as well. Tailored patterns were developed to create a more refined fit, facilitating a forward-leaning posture that improved aerodynamics. Large pads filled with urethane foam were intricately stitched into the waist and back, offering an added layer of protection. As racing speeds surged, leather suits evolved dramatically, ensuring that riders not only exuded style but also enjoyed the utmost safety and comfort on the track.

1980s

The advent of shirring and knee sensors marked a significant leap in functionality

In the 1980s, the hang-off and knee-down riding styles solidified their status as essential techniques, prompting a significant evolution in leather suit design and functionality. In 1983, a pioneering development emerged when the first domestic manufacturer introduced a system featuring a sewn-in base, onto which specially molded plastic knee sensors were securely bolted. This marked a pivotal advancement in rider protection. By 1985, the knee sensors underwent an upgrade to cowhide with Velcro attachments, enhancing ease of replacement while garnering acclaim for their superior sliding properties. However, their thinner construction resulted in rapid wear for some riders, coupled with a higher price point. In response to these challenges, a more resilient plastic variant was developed and adopted in 1988, establishing the foundation for today’s sophisticated 3D knee sensors. Simultaneously, the necessity for flexibility amid dynamic rider movements spurred further innovations. A key advancement was the introduction of shirring in 1983, which involved integrating stretch materials with leather to enhance mobility. This technique was strategically applied to high-mobility areas such as the shoulders, hips, and knees, significantly improving the rider's range of motion. Achieving an optimal balance between flexibility and durability required considerable expertise, as the interplay of leather thickness and mesh punching influenced overall performance. Protection features evolved considerably, incorporating outer patches filled with felt cotton at the shoulders, hips, and elbows, alongside inner patches crafted from compression foam. The integration of plastic knee cups provided substantial protection, which evolved in 1987 to extend coverage to the shins. Additionally, the fundamental patterns of leather suits were re-evaluated during this period, transitioning to a three-dimensional design that conformed seamlessly to the rider's physique. Adjustments to the angles of the elbows and knees resulted in a marked increase in mobility. A particularly innovative solution arose from the extreme heat experienced during the Suzuka 8-Hour race, where riders, unable to endure the sweltering conditions, resorted to cutting holes in their leather suits. In response, KUSHITANI staff, concerned about maintaining tear strength, meticulously re-punched holes in less critical areas, paving the way for the development of perforated leather. This innovation not only enhanced ventilation but also contributed to a lighter design in leather suits, which had become increasingly cumbersome due to added protective features. The advancements achieved throughout this decade laid the groundwork for the high-performance gear that modern riders enjoy today, reflecting a commitment to both safety and sophistication in motorcycle apparel.

1990s

Introducing the innovative adoption of printed designs and the cutting-edge development of the X-pattern

The 1990s brought a dramatic change in suit design. Previously, styles were determined by leather panels and color combinations, but new silk-screening techniques allowed for printed graphic designs. This innovation made the suits lighter and enhanced their flexibility, significantly improving fit and mobility. Today, the introduction of water-repellent leather has further refined fit, making sharp leather designs more popular. Sponsor patches that were once sewn on are now primarily printed. In 1991, Kevlar knit was added in key areas to increase mobility. This stretchy material led to the creation of new patterns, including the foundational "X-pattern" seen in modern suits. By 1996, even stronger Zylon knit was introduced, offering over twice the strength of Kevlar, reinforcing critical areas without sacrificing safety.

 Protection also advanced significantly through the development of new materials. In 1993, the high-performance shock-absorbing material "K-foam" was introduced, enhancing safety in the shoulder, elbow, and waist areas. In 1988, polyethylene foam combined with hard resin pads was adopted for knee protectors, where the outer hard resin repelled impacts while the softer interior absorbed shock. This combination, akin to helmet technology, required careful consideration for optimal performance. Furthermore, in 1996, the elbow protectors featured a blend of polyethylene foam and HP-1 shape memory foam pads, a technology that remains in use today due to its exceptional effectiveness. The 1990s also saw significant advancements in tire and suspension technology, with GP500 engines approaching 200 horsepower. As the risks of high-side crashes and other dangerous situations increased, these innovations in materials and techniques played a crucial role in supporting riders through challenging conditions. It is no exaggeration to say that these advancements were instrumental in enhancing rider safety and performance during this dynamic decade.

2000s

Evolving into a leather suit that offers unparalleled stretch and freedom of movement

In the 2000s, road racing around the world saw significant advancements in both machines and riding techniques. The top class transitioned from 2-stroke GP500 to 4-stroke Moto GP starting in 2002. Similarly, GP250 evolved to 4-stroke 600cc Moto 2 in 2010, and GP125 became 4-stroke 250cc Moto 3 in 2012. 

Young riders began adopting new styles, leaning deeper into corners with bank angles exceeding 60 degrees in Moto GP, sometimes even dragging their elbows on the pavement. This shift required a reevaluation of leather suits to enhance mobility, leading to the inclusion of elbow sensors for added protection. As a result, leather suits evolved into a new generation that utilized Zylon knit more extensively and redefined patterns to improve movement. These suits could be described as true sportswear, allowing riders to perform stretching exercises while wearing them. 

Protection also saw enhancements. In 2008, an upgraded version of K-foam, called "K-foam Plus," was developed, featuring low water absorption to minimize sweat buildup. Today’s top models incorporate K-foam Plus in the shoulders, waist, collarbone, sides, and tailbone, with HP-1 in the elbows and a combination of polyethylene foam and hard pads in the knees. While no suit can guarantee 100% injury prevention, these improvements significantly reduce the risk of injury. The use of aerodynamic back hump, now standard, not only aids in aerodynamics but also helps protect the head and neck during falls by minimizing initial contact with the ground. Additionally, these humps can be outfitted with removable inners for airflow or a hydration system, like a camel bag, which has become essential in events like the Suzuka 8-Hour race and popular among riders during hot sprint races. High-end leather suits now feature Proto-Core leather, treated with fluorine for exceptional water resistance. This treatment prevents rain and sweat from soaking in, reducing wear and tear while enhancing fit and flexibility. Looking ahead, protection will continue to evolve.The real safety that KUSHITANI pursues in our leather suits lies in achieving a high-level balance between protection and mobility.