Can this be used under a motorcycle helmet, or is it too thick?

This winter hat may be too thick, but it all depends on the person wearing it.

will itfit under a hard hat?

I think it should might have to adjust your hard hat a little.

does it cover one's ears? i want a cap that does not cover the ears.

I have a very large though not freakish 7 5/8 head, and this is the only fleece cap I have found that fully covers my ears. That includes hats with multiple sizes up to so-called XL. So please for the love of everything - if you are reading this Carhartt - do not make it smaller.

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