Seat Comfort Mod (plan A) - Kawasaki Versys Forum
 
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post #1 of 14 (permalink) Old 09-19-2010, 02:08 PM Thread Starter
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Seat Comfort Mod (plan A)

Like many of you, I want to gain more comfort on longer rides and would like to achieve it without dropping $400-600 on an aftermarket seat. That being said, I scoured this site, the ADV site and others, in the attempt to gain enough positive feedback that I could forge ahead with a plan to make an economical mod on my own.

Initially, I considered purchasing a new top layer of comfort foam and may come back to that idea if necessary. However, I keep seeing a lot of positive feedback with the gel cushion that WalMart sells in the automotive section. Even saw where some of the Airhawk users converted to this inexpensive, and seemingly effective cushion.

After a collection of ideas gathered from 357,984 different posts , I devised plan A which consists of the following.
  • Source gel cushion from WalMart
  • Remove staples from front portion of seat to expose foam
  • Remove foam and filet a section of foam from bottom (a- lowers seat height, b- accomodates space for said cushion, c- corrects downward slope to tank, d- maintains OEM seat shape on top, e- dishes seat to be more saddle-like)
  • Trim section from gel cushion to fit base of seat pan
  • Insert cushion, install foam, pull seat cover in place, staple to secure

My goal was to lower the seat, maintain stock appearance, increase comfort, and minimize cost. So far, I can say that I have achieved most of these goals, the only uncertainty is increased comfort...time will tell. One thing I am sure of, is that I have read enough on this topic that I'm confident that I can continue to modify the seat, if necessary, in order to maximize comfort (i.e.- modify contour, add comfort foam, etc).

I can't take credit for inventing this mod, as it is an accumulation of ideas I've sourced on this forum and many others. I'm so glad that I attempted the project, and send out a big to the folks who have posted their info and success...it was an encouragement and education.

Now, I'll need to make some time to go for a long ride and put it to the test; it feels good in the garage. Total time researching= , too much; total time to modify= about an hour and a half (start to finish). Pics below.

Last edited by bwwoodard; 09-19-2010 at 04:34 PM.
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post #2 of 14 (permalink) Old 09-19-2010, 02:11 PM Thread Starter
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Filet-o-seat

Drew a pattern, fileted the seat and tapered as desired.
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File Type: jpg Versys seat 058.JPG (97.8 KB, 548 views)
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post #3 of 14 (permalink) Old 09-19-2010, 02:13 PM Thread Starter
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Cushion implant

Trimmed and inserted cushion....
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File Type: jpg Versys seat 057.JPG (149.0 KB, 591 views)
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post #4 of 14 (permalink) Old 09-19-2010, 02:18 PM Thread Starter
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Tools and supplies

One said cushion, screw driver (to pry stalpes), needle-nose (to pull stubborn staples), staple gun, and the Hoffritz turkey carver
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File Type: jpg Versys seat 064.JPG (252.2 KB, 565 views)
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post #5 of 14 (permalink) Old 09-19-2010, 02:22 PM Thread Starter
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The sum of the parts = the product

Looks stock!
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File Type: jpg Versys seat 061.JPG (120.8 KB, 511 views)
File Type: jpg Versys seat 062.JPG (179.5 KB, 553 views)
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post #6 of 14 (permalink) Old 09-19-2010, 02:27 PM Thread Starter
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Bonus

That's not all....

No project would be complete without having parts left over. So, when you have lemons, make some lemonade!

I have enough cushion left to re-position inside the cover, then sew in, and have an additional cover to fit on the Versys if desired or the XT225
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File Type: jpg Versys seat 065.JPG (212.5 KB, 530 views)
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post #7 of 14 (permalink) Old 09-19-2010, 05:21 PM
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Sounds and looks like a job well done, keep us informed how the mod performs on a long ride, i'm interested to find out.
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post #8 of 14 (permalink) Old 09-19-2010, 08:12 PM
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the REI self-inflating stadium cushion is way better than the gel, IMHO......
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post #9 of 14 (permalink) Old 09-19-2010, 08:20 PM
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Do you guys use any hot air or steam to replace seat cover?
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post #10 of 14 (permalink) Old 09-19-2010, 09:11 PM Thread Starter
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Quote:
Originally Posted by tomla View Post
the REI self-inflating stadium cushion is way better than the gel, IMHO......
Yep, some good reviews on this method.

I thought about that, and still may incorporate an air cushion/bladder in the seat, if needed. In the many posts I searched and read, here's a positive review on the air cushion. My concern is/was how long will the cushion hold up??


Link below, post #16, was posted by our member, Atgatt (who, by the way, is MIA). I sent him a PM with no reply. He hasn't posted here in months...just vanished. Anyone know what happened to him?


http://www.kawasakiversys.com/forums...light=rei+seat

Last edited by bwwoodard; 09-19-2010 at 09:38 PM.
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post #11 of 14 (permalink) Old 09-19-2010, 09:17 PM Thread Starter
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Quote:
Originally Posted by blipco View Post
Do you guys use any hot air or steam to replace seat cover?
Since my seat cover had already been shaped and formed to my seat, heat wasn't necessary. I just placed the cover back into natural shape and tacked it at random spots to get the overall position, then began to tighten the cover as needed and add more staples until finished.

Looking back, I can honestly say it was a piece of cake. I was patient and had read a lot about it, so I was prepared.
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post #12 of 14 (permalink) Old 09-19-2010, 09:38 PM
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Looks good from the pictures. I would be interested also to see how it holds up on a long day.
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post #13 of 14 (permalink) Old 09-19-2010, 10:23 PM
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I definitely need to buy a pneumatic stapler, some non-rusting staples and get this mod done this Winter while the snow flies during my Winter 2010 FarkleFest. Was going to buy a Baldwin (and still may) but if I can make a workable seat and save the $$$ I can use that for other farkles.

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post #14 of 14 (permalink) Old 10-03-2010, 04:56 PM Thread Starter
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Originally Posted by bwwoodard View Post
Looks stock!

1 hour in the saddle today= much better!

I was "planted" on seat, not sloped downward toward the tank...that makes a big difference.

So far so good!
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