How I messed up my KTM Duke's seat by doing mods worth Rs 8000

I test rode the Triumph Speed 400 and it felt like sitting on a sofa. So I decided to keep my motorcycle and this is where the mods began.

BHPian nr07 recently shared this with other enthusiasts.

I know I am a bit neurotic, but I hope some of you can see how small things can affect our lives when sometimes we can't undo the wrong we have done.

It starts with Speed 400

I rode my Duke 200 BS6 for 10,000 KMs, and my BS4 Duke 125 before that, and have gone on long trips. Last November, I went to Meghalaya and hurt my tailbone, which gives me problems to this day. I ride leaning slightly forward, taking pressure off the tailbone, and it works.

I had an accident around 1.5 years prior (my first fall from a running motorcycle which needed plates and screws on my wrist to fix). This made me a very safe, conservative rider, not riding out of passion. However, the Meghalaya trip brought back my riding passion, and I was seeking an upgrade from my Duke.

This made me test ride the Speed 400. After a 60 km trip to the nearest showroom on my Duke and hopping onto the Speed 400, it felt like sitting on a sofa.

The first seat mod

This was in December 2023. I decided to keep my Duke and applied a gel pad to my Duke 200 BS6 seat on an impulse decision (as I later learned how soft seats, like those on the Speed 400, are not actually good for long rides). The gel pad mod did not feel like a great upgrade at that time and only felt like a slight improvement. However, it caused a series of unfortunate events.

This mod was done without cutting the seat. A 12mm gel pad was added to the original seat, and on top of that, a soft foam was added. I did not have any problems with comfort, but seat height was an issue. I could manage the seat height as I was barely tiptoeing, but sometimes I would be in uncomfortable situations.

Attempt at a fix from someone who does not know what he is doing

Six months later, I needed a second surgery to remove plates and screws. After two months off the bike and thinking about fixing the seat height problem, as that would put me at risk, I got the original seat cut from a local shop. I live in a small town, and going to the first modder with my bike, 55 km away, was not an option at that time. This was the first mistake.

Here's what he did

Opened the seat, removed the gel foam and the soft foam cover on top, cut the original bike seat, put the 12mm gel pad back in, and the soft foam cover on top. It hurt me badly, but I wasn't sure as I was off the motorcycle for two months, so I thought maybe I was not used to it. I rode for another two weeks and ended up hurting my testicles (I lean forward while driving because of the tailbone issue I mentioned earlier, and the seat was messed up). This was terrible. How do I describe this new seat? It felt more comfortable to sit on a wooden chair after sitting on this seat for 10 minutes and driving.

Going back to the original modder with mixed results

I took the seat to the original shop which did the first mod. He said the original foam was cut too much and there wasn't much he could do without ridiculously increasing the seat height. He ended up putting foam from another bike on it. It felt softer, but the soft part sank in, and after an hour or two of riding, my sit bones got sore, which wouldn't have happened previously. Plus, I feel that the soft foam sinks, and after that, I am sitting on the hard part. I wasn't sure of its efficacy on longer rides.

Starting from scratch with Sahara seats

I ate the loss and decided to start from scratch. This is where Sahara Seats comes in.

To remove all variables of previous mess-ups, I ordered a new original seat online and sent it to Sahara Seats directly, as I can see they have a very good reputation.

I thought this would be the end of my worries if I ate some cost. I said the budget was not a constraint, and the seat height increase should not be too much. They initially suggested that a rubber foam would be enough. They scrubbed the original seat slightly (nothing was cut as I recommended against it), and put a rubber foam and another soft foam on top of it.

Opinions on the gel pad were mixed, and fearing too much increase in seat height, I decided not to go with the gel pad.

They took 1500rs, which was lower than what they quoted initially, and overall their support was good.

This is the photo after scrubbing.

This is the photo after adding rubber foam.

Did Sahara Seats mess up?

I received the seat, and it felt hard. I said okay, I don't mind if it's firm, as it is actually good for long rides. I rode a few small distances locally, but my sit bones started getting sore from day one after riding on this seat. Even though I have done only small rides, my sit bones have been sore since the day I installed the seat (it has been around six days).

I am a little afraid after all the money spent and all the hassles, I don't want to get another injury because of this. I know Sahara Seats is very good with classic retro-type bike seats that come with thick foam, but I rarely have seen other people get their sports bikes done from them, and I am not sure how many Dukes they have done.

Is it possible they have messed this up? Maybe removed some support layer during their scrubbing of the seat? Or does the seat really need a break-in period since it's new? They said it needed a break-in period, and the seat was even harder before they scrubbed.

I do not remember having butt issues when I had the original seat or when I bought the bike.

I have now ordered a 6mm gel pad from them and am hoping to get it added to the seat locally without cutting anything (God help me!). Basically, at this point, I am willing to compromise on the seat height problem, but my seat comfort issues are not sorted. Haha. All of this was a total waste.

TLDR

Modded the original seat of Duke 200 BS6 without cutting the seat and added a 12mm gel pad and soft foam on top. Did not have comfort issues but did have a height issue. Tried to fix the height issue by cutting the original seat, but it actually messed up the support from the seat and ended up injuring me.

Went back to the original modder who did a "jugaad" and put soft foam from another bike, but I was not happy, plus the bones hurt as the seat sank in on longer rides. It was also really tall!

Started from scratch with Sahara Seats with a brand new original seat sent directly to them. My butt is sore since the day I installed the seat (it has been 5-6 days).

Piling up of cost:

• 3000rs for the original mod which worked but had a height issue.
• 300rs for cutting the seat, which ruined the seat.
• Another 800rs to the original modder to somewhat fix it with some compromises that are not working for me.
• 1500rs to buy and get a brand new original seat.
• 1500rs to Sahara Seats for their mod of rubber foam.
• 1150rs sent to Sahara Seats to get them to ship a 6mm gel pad and one soft foam - I am here.

I might have to end up selling the bike. Very upsetting situation.

Here's what BHPian scorpian had to say about the matter:

Instead of doing all these experiments just order a brand new factory seat and be done with it. You will end up spending more and more with all this aftermarket seat stuff and never get it perfect.

Here's what BHPian Captain Slow had to say about the matter:

I'm sorry to say this but the OEMs are not stupid! They must have done enough R&D on the seats before releasing it on a motorcycle! I find it amusing that people think some Rao or Pao seats can fix their seats and make them better.

Stick to the OEMs. Royal Enfield does offer better quality seats on a variety of their bikes.

What is done is done - Just get yourself a brand new OEM seat and settle with it. While you are at it, buy yourself a good pair of cycling shots to help save some important organs!

Here's what BHPian Cyborg had to say about the matter:

I feel for you as I know these things can be painful - literally and figuratively as well. At the outset I say, forget what happened and get a new seat from the factory which will close this chapter.

The Duke family is not best known for comfort be it seat or suspension-wise. Your best bet would be to take this loss as experience and get a new bike which fits your parameters.

Check out BHPian comments for more insights and information.