Honda CB500 //
#BOLT44
Using a Honda CB500 as a base for a custom build isn’t very common — but that doesn’t mean it lacks potential. In this case, we chose the donor bike based on the needs and preferences of the client.
The owner of this beauty was looking for a bike that was compact, easy to ride, with small dimensions and a clear scrambler style. After evaluating several models — like the Suzuki GN or the Yamaha XT — we decided on the 1992 Honda CB500, which we felt was the perfect choice.
As we’ve mentioned before, at Bolt Motor Company, a workshop specialized in custom motorcycles, we work in two ways: the client can bring in their own bike, or we can source one ourselves. In this case, it was the latter. Either way, we always aim to make things easy — whether that means finding the right bike or thoroughly inspecting the one the client provides.
Once the bike arrives at the workshop, two parallel processes begin. On one hand, our mechanics inspect every part to determine what can be reused and what needs replacing. They also make sure the bike runs perfectly before we begin the customization process.
At the same time, our design team begins working on the final render so the client can give their approval. Once we get the green light, the disassembly begins — and that’s when the real fun starts.
HONDA CB500 CUSTOMIZATION – STEP BY STEP
Up front, we mounted the entire front end from a Suzuki GSX750R, including forks, calipers and brake discs. The triple clamps were CNC-machined by Bolt Motor Company, and we fitted Goodridge braided brake lines.
One of the key features of this build is the fuel tank. We wanted something raw and rugged, but with personality and clean visual appeal. In the end, we chose to use the original tank, applying a rusted steel treatment to give it a beautifully aged, patinated look.
The seat features stitched detailing in rust tones, with a rain-resistant treatment to keep it in perfect shape no matter the weather.
We modified the rear subframe, giving it a sharp upward line and fitting a perforated metal side panel to reinforce the off-road, utilitarian vibe. The exhaust was also reworked to better match the enduro-inspired look.
Without a doubt, the most challenging part of this project was installing spoked wheels. Adapting cross hubs to fit with spoked rims and achieving that rugged scrambler stance was no easy task. The choice of chunky knobby tires was the perfect final touch.
The entire electrical system is brand new, built with Motogadget components, a LED headlight, and a cross-style tail light.
