Ever dreamt of the perfect adventure bike—but realized no manufacturer actually builds it? Yeah, same here. But instead of ranting on forums like the rest of us, Andy Scutt went full mad scientist and built his dream ADV machine from scratch.
The result? A 2015 Honda CRF250L with a CB500X twin-cylinder engine shoehorned in. It’s wild. It’s fast. It’s reliable. And honestly? It’s probably better than anything the big brands are selling right now.
Let’s break this beauty down.
What Is This Frankenbike?
At its core, it’s a CRF250L chassis—lightweight, steel-framed, rugged. But Andy dumped the stock 250cc single and slotted in a twin-cylinder CB500X engine, instantly doubling the horsepower and tripling the torque. All in a 156kg, fully-fuelled ADV weapon that’s comfy on the highway and equally capable off-road.
This isn’t just a cool custom. This is what manufacturers should be making.
Why Build It?
Simple: No one makes a lightweight twin that can actually adventure.
Andy’s done it all—KTM 690s, rally builds, endless modding. But he hates vibrating singles on long rides (don’t we all?). What he wanted was:
- A smooth twin engine
- Under 160kg wet weight
- Serviceable anywhere in the world
- Capable of multi-day, 12-hour off-road slogs
Manufacturers? Nowhere close. So Andy rolled up his sleeves and made it himself.
The Specs: Built To Roam, Built To Rip
Let’s get into the juicy details.
Engine Swap Magic
- Donor Engine: CB500X twin
- Power: Around 47 hp
- Torque: Way more than the original 250L (like, 3x)
- Weight Difference: Just +9kg over stock
That engine sits butter-smooth at 80mph all day. Off-road? It’s a mountain goat with manners.
Frame & Fabrication
- Stock CRF250L steel frame
- Custom engine mounts & cradle
- Modified for quick engine removal (~30 mins)
- Bolt-off rear subframe—replaced after a loop-out incident (ask Andy about that one)
Steel means field-repairable anywhere. Snap it in Mongolia? Any village welder can fix it.
Suspension & Wheels
- Front End: CRF450X KYB forks
- Rear Shock: YSS 300 Rally (extra ground clearance)
- Wheels: SM Pro 450X with custom cush drive (no slipper clutch here)
- Handling: Stable, plush, totally composed—feels like a factory rally rig
Practical As Hell
Everything is designed for real-world adventure:
- Honda parts throughout: air filters, plastics, ECU—easy to source worldwide
- 12.5L fuel tank = ~200 miles range
- Clever hydration system: magnetic drinking hose, no sweaty backpack
- Custom exhaust: quiet but crackly, tuned for smooth performance
- Maintenance: 6,000–7,000 mile oil intervals, valve checks every 28,000 mi—none needed yet
And yes, this thing has survived 24,000+ miles, mostly off-road. No drama. No breakdowns.
Why Doesn’t This Bike Exist Off the Shelf?
That’s the million-dollar question. Andy’s even shown it to Honda UK. Eight years later, no manufacturer has stepped up and we can safely say no manufacturer will build such a bike. A unicorn motorcycle like this can and will easily eat into the sales of the big and expensive 800/1200cc ADV bikes which bring in a lot more revenue than an inexpensive, repair-anywhere, do-it-all adventure motorcycle.
Closest thing? Maybe the Cove 450 Rally, but:
- Heavier
- Shorter service intervals
- Still a single-cylinder
Even the lightest factory twins—like the CB500X—come in 30–40kg heavier than Andy’s build after upgrades. That’s like strapping a passenger on before packing your luggage.
Final Thoughts: Manufacturers, Take Notes
This build proves what’s possible when you mix ingenuity with reliability. Honda’s got the parts. The community’s got the demand. The only thing missing? A company brave enough to bolt it together.
Until then, Andy’s bike is the dream. One man, one vision, one seriously capable machine.
If you want to know more, get in touch with Andy on his Instagram account – IG – “bike_build_ride“
The man himself – Andy Scutt
