Issue: During a long road trip on my KLR650 my butt went numb after a few days of riding and I stopped at an automotive store to pick up a gel seat as a temporary solution. I found a gel seat meant for a car and quickly modified it to strap on to my 2008 KLR650. As it turns out I really like the gel seat and want to keep it as a permanent solution for the KLR’s butt-numbing rides. Here’s the issue – with the gel seat on top of the stock seat I’m now sitting too high on the bike.
Solution: While installing my new K&N air filter for the KLR650, I removed the seat, looked underneath and the idea just hit me. Why don’t I remove the upholstery, shave down the foam inside the KLR’s seat to lower myself back to the stock height? So I gave it a try and it worked! Here are the instructions and how I did it.
Instructions: (see video below)
- Remove the KLR’s seat
- Using a small screwdriver, remove the staples from the upholstery. I went about half-way down the seat but you can take the entire seat apart if you choose.
- Peel back the upholstery and carefully remove the plastic that’s between the foam and upholstery. You’ll need to use the plastic again so be careful not to damage it.
- Mark the area and depth you want to remove.
- Using a serrated blade, slowly cut through the foam and be careful not to tear it. This was very much like filleting a fish.
- Once you have the cut to the desired depth and remove the excess foam (I removed approx 2″) you should try the seat on your KLR to make sure you got the height right.
- Reinstall the plastic using tuck tape to re-seal the edges and patch any other holes.
- With someone’s help, hold the upholstery in place and use a regular staple gun to secure it in place.
- Put the seat pack on your KLR and you’re done.
Results: This worked out great for me but I wouldn’t recommend doing this mod unless you have a gel seat or Air Hawk to place on top of you KLR’s lowered stock seat. I now have the comfort of the gel seat and I’m sitting slightly lower on the bike which reduces buffeting at speed and makes it easier to reach the ground while stopped. Lucky my idea worked because the was no turning back!