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Discussion Starter · #1 ·
As many who have ridden a passenger have heard from riders the passenger seat is not always heaped with praise for its comfort. I too have heard these complaints from my wife and my son who both said the seat was too hard for anything other than very short rides. :( I decided to try some experimenting. :idea:

I began by removing the seat cover by pulling out the staples on three sides. I left the staples in the rear on because there are some under the mounting bracket. I figured the only way to get them back in was to drill out the rivets holding the bracket on and that was more work than I wanted to get into. Leaving one side still attached keeps it in a semi original position when its time to reattach it.

I found the seat cushion is one solid piece of molded foam. I went to the local fabric store with the wife and we found some foam padding there. They have two different types and I bought the green higher density foam, which is a little firmer. The other stuff was very easy to compress so I didn’t think it would work very well for this sort of thing.

I bought a one-yard length of the two-inch thick foam. My idea was to cut a piece of foam and add it to the top of the existing foam pad without having to get a whole new cover made. I actually experimented several times with different styles and sizes of foam pads. The one that finally worked best was when I flipped the seat upside down on the foam and cut around it. This gave me a 2 inch thick piece of foam that was the same size as the top of the seat cushion. Next I took an electric carving knife and beveled the top edge all the way around this new top pad. From my other ‘test’ pads I had learned doing this made the pad fit better under the cover. It also made it so the new padding didn’t show under the cover.

I now tucked the pad into the cover and then pulled it back over the seat cushion. This took several tries, as the new pad tends to move around or bunch up as you stretch the cover over it. I found the best way to get it in is to start the new pad so it’s back edge is hanging over the back edge of the seat. This way when you stretch the cover on and pull it over the front of the seat it moves it into correct position.

I started reattaching the cover up one a few inches and then doing the same on the opposite side to keep it aligned properly. I decided to use very small screws in place of the staples and that worked out really well. The cushion is thick enough so the screws will not hit anything. Once the holes were made in the seats plastic base and the cover by the screws, each succeeding time I had it off it was really easy to align them back up! The finished product came out very nice! :D Appearance wise it’s a little taller and has a more rounded appearance but not very much.

So far the only problem I encountered was the strip of leather (vinyl?) that the passenger can hold on to doesn’t fit over the seat as well now. I think that can be lengthened without too much hassle though.

The final verdict by the riders? :?: They love it!! Both the wife :D and my son :D have given it the big thumbs up for comfort! Both say it is a huge improvement over the stock padding!! Both originally said it would be nice to have a wider and softer seat but it’s not such a big deal now that the seat is so cushioned.

Total cost of the project? Under $15.00 The foam set me back $12.99 for one yard. I also used about a dollar’s worth of small screws. I have about three hours of time invested in all the ‘test’ pads and the final pad design. No it’s probably not as comfortable as an aftermarket seat but it is a lot cheaper! (And not back ordered either!) One note here, I actually purchased another spare seat to do this little experiment on in case it went bad. I was too chicken to mess up my original seat and didn’t want any down time.
 

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Discussion Starter · #4 ·
Highly recommend trying it! It doesn’t cost much, doesn’t take very long, and if you don’t like it you can go back to the original seat.
 

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Thanks for sharing this. I'm going to try it.

Joe
 

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Padded my Driver seat

Studly,

Good job with the passenger seat. I have done something like this for the drivers seat. I was getting serious butt burn. Same directions as yours.
 

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Discussion Starter · #8 ·
Eventually I would like to go with a nice aftermarket seat but there are other goodies on the list first! I figured I would try this experiment and see if I could come up with a short term solution. So far it’s getting rave reviews from the riders. :D

Hey BriMan, what did you do to your drivers seat? I'm also working on trying some modifications to that too, but so far my results have been mixed.
 

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Discussion Starter · #10 ·
I started working on the drivers seat now. I cut out some of the existing padding and then added softer stuff to the center. Like the rear seat it's sort of a trial and error thing and this is my third test padding. Tested my most current work today with a 50 mile ride and it felt better on the backside. Big test will be tomorrow. Riding from Akron to Cleveland to Pittsburgh!
 

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So far only worked on the rear seat. Took it to a local upholsterer and for 40 dollars he took the seat apart (no gel there what a rip off by suzuki) and replaced foam with layer of high density and a top layer of low density. broadened seat inch to inch and half on each side and another inch in height. Did the work on the oem gel seat which frankly is worse than the stock rear seat.

Over the winter I might have him do some work to front seat but so far am happy with it for short to moderate rides.

tony
 

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Discussion Starter · #12 ·
The modified stock seat performed very well on my recent trip to Pittsburgh. It felt better than the original stock seat but I'm thinking it could still be better. I want to find a gel pad and add it in to see if that helps. Not much riding weather left to give it a really good test though.

Anyone know what a decent price to pay for a gel pad insert is?
 

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Pass. seat Mod.

I actually went the other way .... I plan on riding solo, and didnt want or like the bulkiness of saddlebags, so I gutted the pass. seat, framed the interior with plexiglass, and had a seamstress through on a velco strip on the front. Now, you would never know it, but my seat is a custom glove box.
 

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Re: Pass. seat Mod.

VolusiaMania said:
I actually went the other way .... I plan on riding solo, and didnt want or like the bulkiness of saddlebags, so I gutted the pass. seat, framed the interior with plexiglass, and had a seamstress through on a velco strip on the front. Now, you would never know it, but my seat is a custom glove box.
Pics? :D


Joe
 
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