Honda XL500 Scrambler

The Ultimate XL500 Scrambler: A Purpose Built Moto Signature Series Build

When you spend as much time around vintage dirt bikes as we do, you learn a few things about what makes them truly special. This 1981 Honda XL500—our latest VMX-style scrambler—came into the Purpose Built Moto garage from a longtime client who wanted a proper matching stablemate for his previously built Yamaha XT500. Our goal? Take the classic XL, keep its soul intact, and elevate it to the next level of performance and style.

A New Breed: Retrocross
We’ve been refining this style through a number of builds—taking old Motocross, Enduro and Dual Sport classics and bringing them into the modern age with just the right touches of refinement, capability, and style.

Retrocross is a term we use to describe the Strand of Design DNA that we've developed across builds like our DT400, XT500 and now the XL500 featured here. The Design direction aims to light a fire in the belly of that teenage boy in all of us. Taking the prolific bikes we grew up around, heard our dads talking about or learnt to ride on and re-imagining them with a sharp eye on clean aesthetics and modern performance upgrades.

The Engine Build
We didn’t hold back when rebuilding the XL500’s heart. Inside, it’s packing a 95mm big-bore piston running at 10.5:1 compression, giving it a new displacement of around 570cc. To feed that beast, we sourced oversized valves, new seats, and guides, then topped it off with a TM40 pumper carb from Mikuni Oz. We’ve also thrown in a strengthened clutch to handle all that extra grunt.

You can really feel the difference when you kick it over—no easy feat—but that added compression and displacement are well worth the extra legwork. This XL now pulls like a freight train and sounds the part, too.

Custom 12-Volt Conversion
Upgrading these old Honda singles to a modern 12-volt system isn’t always straightforward. Off-the-shelf ignition upgrades for this particular model proved elusive, so we got creative. We rewound the charging coil, sourced a specialized regulator/rectifier, and wired it all through our Purpose Built Moto black box under the seat. Now, we can run 12-volt LED lighting, A clean aftermarket dash, and the PBM Black Box and Switch set up.

Suspension & Running Gear: Built for Real-World Riding
On the front end, we replaced the stock forks with a fully rebuilt and lowered late-model motocross setup, courtesy of Costanzo Racing. They dialed in an ultra-plush feel that still soaks up the rough stuff without rattling your fillings loose. Out back, a custom set of YSS shocks lifts the rear and keeps the bike balanced and agile on or off-road.

For the wheels, we laced Excel rims to a DR650 hub at the rear, converting this old drum-braked Honda to a modern disc brake setup. With a Brembo caliper custom-mounted and a neat PBM fluid reservoir, the stopping power finally matches the motor’s new muscle. The wheels run Pirelli Scorpion Rally STR tires—19" front and 17" rear—perfect for a scrambler that sees more street than dirt but still wants the option to roam off the beaten path.

Fabrication & Bodywork: Simple, Functional, and Clean
We kept the aesthetics honest. The star of the show is that iconic XL500 steel tank. With its unique shape, it didn’t need over-the-top bodywork stealing the spotlight. Instead, we kept the fenders simple—hand-shaped metal that fits tight and neat. Fork shrouds were custom made from aluminum to deliver a classy finish. Up front, a Purpose Built Moto Flashpoint 4.5" headlight sits in a custom housing, bracketed neatly with a nod to old-school racer style. Hollow-tip LED indicators tuck in close, keeping the front end tidy.

Minimal side covers neatly hide the battery, wiring, and air filter. A short custom rear fender holds our Omni LED indicators and a tidy license plate bracket. Every piece of bodywork was done with that Retrocross “less is more” approach—simple lines, no unnecessary flash. This preserves the classic XL feel while adding our modern Purpose Built Moto touch.

Controls & Cockpit
Up top, you’ll find Renthal fat bars, PBM three-button switches, under-bar mirrors, and a Daytona Deva digital dash—giving you all the info you need without disturbing that clean look. The ignition system is upgraded with our soon-to-be-released mini key and relay setup. Combined with Domino grips and rebuilt brake components, everything you touch feels top-notch and ready to roll.

Exhaust Build

We fabricated a custom header and fitted it with an FMF Power Bomb. It flows into a shortened Staintune muffler—pure old-school style. The result is a crisp, solid sound that’s not too loud but undeniably more serious than stock. It fits the era and character of the bike perfectly, adding to that Retrocross flair.

Finishing Touches: Paint & Details
Once the bike stood on its own two wheels and we could see the final shape, we chose the colors. That classic XL500 tank guided us: bright red, bold black, and a subtle silver pinstripe to elevate the finish. Pop Bang Classics laid on the paint and details, including a modified XL500R decal and our Purpose Built Moto signature, marking this as a top-tier build.

With subtle branding and tasteful sponsor logos, we’ve created a balanced blend of heritage and modern capability—a Purpose Built Moto Signature Series build. When you see that signature on the tank, you know you’re looking at the best of what we do.

Make sure to check the build release over at PipeBurn.

On the Road
This XL500 rides as good as it looks. The engine pulls strong, the suspension soaks up the bumps, and the upgraded brakes deliver increased confidence. With our careful selection of updates, the XL500 Scrambler is an ultra versatile ride.

The nostalgic feeling created by these big singles is a universal language understood by all riders. That's why these bikes have remained so popular for decades after they've been outdated by engineering progress.

It wasn’t quick or easy, but the reward is obvious. This Honda XL500 scrambler embodies the Purpose Built Moto ethos: craftsmanship, performance, and timeless style—stamped with a new name that reflects the evolution of our vision. It’s Retrocross at its finest.