Reduce Seat Pain During Long Rides! DIY Installation of a Gel Pad (GEL-ZAB)

DIY Gel Pad Installation in Your Motorcycle Seat: Say Goodbye to Seat Pain

One of the inevitable challenges for riders who enjoy long-distance touring is seat pain. After hours on the road, that familiar discomfort begins to set in. Many riders, including myself, have wondered if there’s a solution to this. Enter the hero: the GEL-ZAB pad!

In this post, I’ll share my experience of embedding a GEL-ZAB pad into my Suzuki Grasstracker seat, discuss its effectiveness, installation process, and why it’s a game-changer for riders.

What is a GEL-ZAB and Why is it Great?

Let’s start with a brief introduction to the GEL-ZAB. The GEL-ZAB is a cushion made from a special gel material, designed to be wrapped around motorcycle seats. Its soft and flexible gel helps reduce pressure on the rider’s seat, making long rides more comfortable. The name is a combination of GEL (from the material) and ZAB (from the Japanese word for cushion, “zabuton”). The GEL-ZAB is a product of EFFEX, a brand of PROTO Inc, based in Aichi, Japan.

Key Features of the GEL-ZAB:

It uses EXGEL® technology, a special soft rubber also used in the medical field, known for its superior flexibility and ability to distribute pressure. This makes it far more comfortable than typical urethane foam cushions.EXGEL® was developed by Kaji Corporation in Shimane, Japan, and the GEL-ZAB products are made domestically.

Types of GEL-ZAB:

Product NameTypeDescription
GEL-ZAB RUniversalWrap-around design that fits most seats
GEL-ZAB DUniversalSlim design for off-road motorcycle seats
GEL-ZAB SUniversalInternal type, 370mm x 310mm, 10mm thick
GEL-ZAB SSUniversalSmall-seat internal type, 250mm x 260mm, 10mm thick
GEL-ZAB CModel-SpecificCustom seat cover for models like Honda Rebel or Cub
Type of GEL-ZAB

Embedding the GEL-ZAB into a Grasstracker Seat!

While you can wrap the GEL-ZAB around your seat, I decided to take it a step further and embed it into the seat for a cleaner look and enhanced comfort. Here’s how I did it.

I opted for the SS-type GEL-ZAB, which is ideal for embedding into the seat.

What You’ll Need:

  • GEL-ZAB (SS-size for this DIY project)
  • Seat removed from your motorcycle
  • Staple gun
  • Replacement staples
  • Scissors
  • Flathead screwdriver
  • Needle-nose pliers
  • Knife (for cutting foam)

DIY Installation Process:

1.Remove the Seat:

Start by removing the seat from your motorcycle.

Decide where you want to place the GEL-ZAB by marking the desired location before you take the seat off.

Marking the desired location 

The SS size I purchased this time is about 10mm thick. While it’s possible to insert the gel pad directly into the seat, the unevenness wouldn’t look good, so I decided to shave the seat this time.

2.Peel Back the Seat Cover:

Use a flathead screwdriver or pliers to remove the staples securing the seat cover.

Peel back just enough to insert the pad.

Peel back the seat cover

3.Cut the GEL-ZAB:

Trim any excess from the GEL-ZAB using scissors to fit it perfectly into the section of the seat you’re modifying.

The slightly whitish area is where the special gel is embedded.
Since it will be embedded into the seat and won’t be visible, it’s fine to cut it a bit roughly.
Cut off the edges on all sides.
Draw a line on the part of the seat that will be shaved.
To avoid making the modification too difficult, I cut away the areas without the gel.

4. Carve the Seat:

Carefully cut into the seat foam using a knife, creating a space for the GEL-ZAB to sit. To ensure precision, measure as you go. Patience is key during this step!

I had a knife I use for camping, so I used it this time to modify the seat.

Since adjusting the depth is difficult, I made a lot of 10mm holes to avoid shaving too much.

I worked while measuring the depth with the depth gauge of my caliper.
When shaving urethane, debris flies around, so I wore a mask while working.
It takes a lot of patience to shave, but it’s finally taking shape.
I kept adjusting while measuring with the caliper, and the gel pad fit perfectly.

5.Reattach the Seat Cover:

Once the GEL-ZAB is in place, staple the seat cover back on securely. Your DIY project is complete!

You can see slight traces of the embedding, but for an amateur job, I think this is pretty good.

The entire process took me about 3 to 4 hours, and while the difficulty is moderate, it’s a rewarding challenge for those who enjoy motorcycle maintenance.

The Grasstracker after embedding the gel pad.

Post-Installation Thoughts:

Benefits of Embedding a GEL-ZAB:

A clean, streamlined appearance that doesn’t detract from the bike’s look

Reduced fatigue during long rides

Significant reduction in seat pain

Potential Drawbacks:

The installation requires some technical skill

Not all seats are equally easy to modify

Specific tools like a staple gun are necessary

Performance on Long Rides:

Reduction of Pain with the Gel Pad

The first thing I noticed after using the gel pad was, “It really makes a difference!” The pain I usually felt after riding over 100 km was significantly reduced, and I could ride comfortably for a longer period. During long-distance touring, where I would normally need to stop frequently for breaks due to discomfort, the gel pad helped reduce the number of stops, and I felt that it even conserved some of my energy.

However, it doesn’t completely eliminate pain.

One point I want to emphasize is that the gel pad is a product that alleviates pain, not one that eliminates it entirely. Unfortunately, no matter how effective it is, it won’t make the pain disappear completely. Especially on long rides, pain in the buttocks inevitably reappears. Even during my Hokkaido tour, where I rode over 400 km in a single day, I definitely felt the benefits of the gel pad, but I still experienced some discomfort in the end.

Still, it’s definitely better than nothing!

Even so, there’s a noticeable difference between before and after embedding the gel pad. The dull pain I used to feel while riding was greatly reduced, allowing me to maintain my concentration more easily during the tour. Particularly when touring with camping, the discomfort wasn’t as draining by the time I arrived at my destination.

Conclusion:

The gel pad is an extremely useful item for riders seeking comfort during long tours. While it doesn’t completely eliminate pain, it certainly reduces it. For anyone planning long-distance rides, especially for extended tours like those in Hokkaido, it’s definitely worth trying out.

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