Just wanting to look something up I did a quick search for an online version of a service manual, well here is the full thing:

Honda CB500(S) 93-01 Service Manual

Well, I’ve been a bit busy lately, blowing some cash on bits for the bike. And even if I say so myself, I’m quite pleased actually. Let’s recap what I’m trying to achieve; My 1996 Honda CB500 is looking a bit tired and rusty, and I’m planning to do a bit of DIY restauration and custom paint work on it to make it look good again.

My wishlist before starting the project was as follows:

1. Replacement footpeg rubbers - CHECK
2. Replacement body panels in order to do a full DIY respray, without the risk of permanent damage to original paint! - CHECK (just require front mudguard, but I’ve got my eye on one already…)
3. Possibly replacement headlight cover
4. Respray of engine & gear box
5. New levers to go with the new handlebar
6. New, more modern looking indicators - CHECK
7. Respray of exhaust, or new one depending on how difficult it would be to get a good finish on the old one.
8. Respray of grab rails and other bits and pieces.

So as you can see, there is definitely some progress there already! Last weekend when the body panels I have purchased got delivered, I did see that I’ve got a long way to go in order to achieve what I want.. The tank I purchased needs a bit of care - some rust removal and dents & scratches to be filled. So I’ve stocked up on Hammerite Rust Remover and also a tube of Body Filler from Halfords. And after giving sanding a shot for a while on Saturday, I’ve decided there’s another thing I’m going to have to invest in. An electric sander.

I’m not yet entirely sure what type I should go for, but at the moment it’s between a regular el-cheapo detail sander or a Black & Decker Mouse. The latter seems to be quite good, as far as I could tell from some online reviews I found. But it’s going to take a bit more time researching before I actually buy one.

So here goes, my updated wishlist:

1. Replacement front mudguard, perhaps a fairing as well
2. Possibly replacement headlight cover
3. Respray of engine & gear box
4. New levers to go with the new handlebar
5. Respray of exhaust, or new one depending on how difficult it would be to get a good finish on the old one.
6. Respray of grab rails and other bits and pieces.
7. Electric Sander

If you own a naked bike (ie. one without a fairing), motorway journeys can be tough. At speeds of over 60-70 mph, a rider on a naked bike is hanging on for dear life, with wind hitting the chest, making it hard to continue at the same speed for longer durations. Often at the end of such a journey you’ll feel more tired than necessary, with shoulders, arms and neck aching. Now this problem occurs because the rider of a naked motorcycle is not very aerodynamic. The wind goes over the front wheel but isn’t guided to go above the rider’s helmet, instead it hits him right in the chest and face.

So in order to solve this problem, there are many many shields available to put on your bike. Now I’m not really a speed freak as such, and rarely go anywhere on the bike that requires motorway driving, however my husband is quite the opposite. He didn’t like the way our Honda CB500 handled at motorway speeds, and thinking he might take it to work sometimes (which involves a considerable stretch on the motorway), he set out to find the perfect screen.

So this is what he came up with:

The Vario Touring Screen by MRA

It is not a very big screen, as can be seen from the pictures. However, the extra spoiler type thing at the top guides the air around you in order to allow extra comfort from a minimal screen. If you compare it to some of the very large screens that are usually found on Harleys and such, this screen is tiny, but still gives more protection than one might expect.

Looks: well as you can see, it doesn’t look very out of place, it’s not much bigger than a standard screen on a faired bike. The smoked grey colour looks nice with most paint finishes, or you can opt for a clear one to make it stand out a little less.

Practicality: Having tested the bike on the motorway last night, my husband found it did help reduce the wind hitting him from the front. It was smoother accelerating to faster speeds without feeling like you might lose control of the bike simply due to wind resistance.

Installation: Well although it’s certainly not impossible, installing this shield by yourself is quite a challenge, especially on a bike like the CB500, which has a relatively small handlebar which is already quite cramped. The two brackets that hold the screen up are quite fiddly to adjust to a good position and they do touch other things on the bike like the disk brake fluid reservoir, which can make a little rattly sound at slow speeds. If you’re not very patient, ensure that you have an extra pair of hands to help you out.

Quality: Since it’s only been installed last night, I can’t comment on whether the finish will last. However, I found it looks quite well made, the edges are properly finished so there is actually no need to put the piping on after installation.

Many people who own older bikes may have thought to themselves – why not have a go at repainting the bike at home.

Well I’ll admit, I’m one of those people. And I have taken matters into my own hand, with those around me being extremely divided about the topic. I am going to repaint my bike, and because I’m inherently a bargain hunter, I will attempt to do so on a small budget (yet aiming for the best possible finish!). So following my usual approach for everything, it will take a lot of work, a lot of time, and perhaps a bit of luck.

Repaint Strategy – in order to minimise risk I am going to paint replacement bodywork for my bike. Luckily, because my Honda CB500 is a very common motorcycle, used bodywork is readily available on Ebay and not very expensive. Below find a step by step guide I’ve set for myself:

Step 1. Purchase replacement bodywork;

- Tank

- Side panels (2x)

- Tail piece

- Mudguard (front)

- Tank shrouds (optional – as I haven’t been able to find any yet!)

Step 2. Repair and Prepare; all body panels will be sanded down thoroughly, any rust removed, dents and scratches repaired as far as possible. Once this is done (I’ve set myself a timeframe of 3-4 weeks to do this, since I’ll only get time in the weekends, and I’m quite lazy really), I will prime all bodywork with a rattle can of grey primer (Halfords – 400ml for £5.99 I think). Two to three layers should do.

Step 3. Design; Now my husband keeps insisting I’m doing all this the wrong way around, but after prep work, or during, whenever I get spare time with a graphics software, I’ll have to come up with a design for the paint work. Keeping in mind I’m a total novice to custom automotive painting, I’ll have to keep it fairly simple, or practice like mad in order to find out where my limitations are.

Step 4. Equipment; Depending on what design I’m going with, I’ll have to get painting equipment. At the moment I’m inclined towards using an HVLP spray system for the bulk of the work, and airbrush the detailing. So I will need to buy the HVLP system, a compressor and perhaps another airbrush (the one I have is very basic).

Step 5. Materials; obviously only if I’m totally sure about the colour scheme, I will need to purchase some paint. Considering I don’t have a professional spray booth, or even a garage to my disposal, I would like to use water-based paint, minimising any health risks I’m exposing myself to.

Step 6. Execution; actually paint the bodywork. I’ll have to do this outdoors in the garden, so will need to pick a few weekends with good weather forecasts… All bodywork will need to stay outside for drying even!

Step 7. Installation; the big swap over from old body to new… Like changing the bike’s clothes! Before I do this I’ll need to make sure the tank I’m currently using doesn’t have a whole lot of fuel in it, because I doubt my landlord would appreciate petrol spills on the driveway.

Step 8. Finishing touches; maybe the custom fever has gripped me so much by then, that I’ll want to do a whole new host of things to the bike, like paint the rims or something crazy like that, change the seat cover maybe? I don’t know… I’ll see once it happens.

Throughout this entire process, obviously I’ll keep posting updates and pictures of how I’m getting along. If you’ve got a project of your own which you’d like to share, please do let me know. The more the merrier!

Well as I’ve already mentioned in the About page, I’ve recently started riding around town on the ‘96 Honda CB500 my husband bought over a year ago. Since he’s bought another bike in the meanwhile, plus we also have got a car, the Honda had been lying idle for a while, but this is no longer the case!

I’m now taking it to office almost every day, and with summer approaching, my use of the bike is only set to increase.

So now that I’m using it full time, I can’t be satisfied with the state it’s in at the moment. It’s like an old work horse, which has collected scars over the years, never kept dry and safe, developing rust and generally looking a bit tattered. But I’m going to change all that and in the process individualise the bike to suit my taste.

Over the weekend, I started on this journey - I bought a tube of Autosol Metal Polish, and went to work, cleaning the metalwork of the bike. After finishing the following can be said:

Good bits:

Bodywork in fair order, requiring a respray though

Seat in good condition,

Good tires & wheels

New handlebar & end weights

but that’s about it - bad bits:

Rusty chrome; headlight, shockers

Flaking paint on engine

Torn footpeg rubbers

Faded black plastic (mudguard, meters, indicators, etc.)

Rusty exhaust & downpipes

Scuffed clutch/brake levers

So my wishlist is as follows:

1. Replacement footpeg rubbers
2. Replacement body panels in order to do a full DIY respray, without the risk of permanent damage to original paint!
3. Possibly replacement headlight cover
4. Respray of engine & gear box
5. New levers to go with the new handlebar
6. New, more modern looking indicators
7. Respray of exhaust, or new one depending on how difficult it would be to get a good finish on the old one.
8. Respray of grab rails and other bits and pieces.