Your Helite airbag vest does one job in the moment that matters, and it does it because of a small metal cylinder you might never think about. The CO2 cartridge is what turns a vest into a deployed airbag in under 100 milliseconds. This guide covers what the cartridge does, the sizes Helite uses, the difference between mechanical and electronic cartridges, and what the dangerous goods rules mean for you in New Zealand.
Why the cartridge is required for deployment
A motorcycle airbag is not powered by anything electrical when it inflates. The inflation comes from compressed CO2 stored in the cartridge. When the system triggers, a pin pierces the seal on the cartridge and the gas rushes out to fill the airbag almost instantly.
On a Helite mechanical system, the trigger is the lanyard. If you are thrown clear of the bike in a fall, the lanyard pulls a key-ball out of the trigger, a spring drives a piston into the cartridge, the seal is pierced, and the gas deploys the airbag. The cartridge is empty once it has fired, which is why it is single use. On an electronic system the sequence is the same at the cartridge end, the difference is what decides to fire it.
The cartridge sizes: 60cc and 100cc
Helite matches the cartridge to the size of the airbag, because a larger airbag needs more gas to reach the right pressure at the moment of impact. The two main mechanical sizes are 60cc and 100cc.
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60cc: about 182 grams, 17 litres of protective volume.
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100cc: about 300 grams, 28 litres of protective volume.
The size you need is determined by your vest, not by preference. Smaller and mid range vests typically take a 60cc cartridge, while the largest sizes and the higher volume vests take a 100cc. Your vest or liner has a label telling you which cartridge it takes, and that is always the number to trust. The golden rule: always replace a cartridge with a new Helite cartridge of the same capacity. A different size or a non Helite cartridge can stop the system working as designed.
Mechanical vs electronic cartridges
This is the part that trips people up, so here is the plain version. The cartridge is not just a gas bottle. On an electronic system it is part of the electronics, which is why it is a different component.
Mechanical cartridges are a sealed CO2 bottle. They thread into the mechanical trigger and the piercing is done by the spring and piston when the lanyard pulls the key-ball. Nothing to charge, nothing to connect.
Electronic cartridges, which Helite calls e-cartridges, carry the same CO2 but include the electronic firing element the vest needs to set them off. They thread in the same easy way, but they are matched to the electronic system rather than the mechanical one.
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e-50cc off road: about 181 grams, 14 litres.
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e-50cc: about 181 grams, 14 litres.
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e-60cc: about 218 grams, 17 litres.
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e-100cc: about 328 grams, 28 litres.
A mechanical vest takes a mechanical CO2 cartridge. An electronic vest takes an e-cartridge. They are not interchangeable, and as with the mechanical cartridges, you replace like for like in the same capacity. A nice detail on some electronic models is the double trigger feature. After the first inflation the airbag deflates and the electronics reset onto a full second cartridge, ready to work again without you doing anything.
Keeping cartridges reliable
An unused Helite cartridge carries a 10 year warranty, so the cartridge itself is built to last if it is stored well. Store cartridges below 45 degrees Celsius and use above 0 degrees Celsius, avoid knocks and shocks, and check for rust or corrosion. We cover the full annual weight check, alongside the rest of your airbag's yearly maintenance, in a dedicated guide.
Dangerous goods classification in New Zealand
A CO2 cartridge is a small pressurised cylinder, so it is classed as dangerous goods for transport. This is normal and nothing to be alarmed about, but it does shape how cartridges can be shipped and flown.
The classification. A small non refillable gas cartridge of this type sits under UN 2037, and CO2 is a non flammable, non toxic gas, which puts it in Class 2.2. That is the lowest hazard division within the compressed gas class. It is the same broad category as a CO2 bike tyre inflator or a soda charger.
On the road in New Zealand. Transport of dangerous goods on land is governed by the Land Transport Rule: Dangerous Goods 2005, administered by NZTA Waka Kotahi. The rule treats goods carried for your own domestic or recreational use differently from goods carried for hire or reward. If you are simply carrying your own vest and a spare cartridge in your own vehicle, you are in the domestic use category and the controls are light, provided the cartridge is properly packaged and within the quantity limits in the rule. The moment a courier carries it for payment, the courier becomes responsible for meeting the rule's requirements for small quantities and limited quantity packaging.
Couriering a cartridge. New Zealand couriers handle Class 2.2 cartridges under their dangerous goods policies, usually as Dangerous Goods in Limited Quantities, and several restrict them to road transport within an island rather than air or inter island sea. If you are sending a cartridge, check the specific courier's dangerous goods policy first, because the rules and the paperwork differ between carriers.
Flying with a cartridge. Helite's own guidance, based on IATA rules, is that you are allowed to fly with two CO2 gas cartridges of less than 200cc, in the cabin or the hold. Air New Zealand also lists gas cartridges fitted into a self inflating vest as permitted. The catch is that airline and airport security still have the final say and can refuse them regardless of the written rule. If you are flying with your vest, declare it, keep the cartridges with the vest so it is obvious what they are for, carry a printout of the IATA regulation to show security, and check your specific airline's dangerous goods page before you travel.
None of this changes how safe the cartridge is to live with day to day. It is a sealed CO2 cylinder. The classification is about transport, not about the risk of having one on your vest.
If you have questions about which Helite model suits your riding, get in touch with our team at contact@helite.co.nz
Frequently asked questions
What does the CO2 cartridge actually do in an airbag vest?
It stores the compressed gas that inflates the airbag. When the system triggers, a pin pierces the cartridge seal and the CO2 fills the airbag in under 100 milliseconds.
What is the difference between a 60cc and a 100cc cartridge?
The volume of gas. A 60cc cartridge weighs about 182 grams and fills a 17 litre airbag, while a 100cc weighs about 300 grams and fills a 28 litre airbag.
Can I use any CO2 cartridge in my Helite vest?
No. Use only a genuine Helite cartridge in the same capacity your vest is designed for. A mechanical vest takes a mechanical CO2 cartridge and an electronic vest takes an e-cartridge. They are not interchangeable.
Do CO2 cartridges expire?
An unused Helite cartridge comes with a 10 year warranty. The annual weight check, covered in our maintenance guide, is what tells you whether gas has slowly escaped.
Are CO2 cartridges classed as dangerous goods in New Zealand?
Yes. A small cartridge of this type is UN 2037, Class 2.2, non flammable, non toxic compressed gas, the lowest hazard division of the gas class. The classification affects transport, not how safe the cartridge is to own and use.
Can I fly with my airbag vest and cartridges?
Often yes. Helite's guidance, based on IATA rules, is that you may fly with two CO2 cartridges of less than 200cc, in the cabin or the hold. Airline and airport security still have the final say, so declare them and check your airline's policy before travelling.