Assembly Line

How motorcycles are made

A small 1958 Honda, the Super Cub, is the biggest-selling vehicle of all time.

stations
8
things upstream
101
raw sources
29
steps from the ground
10

The short version

A motorcycle is a steel or aluminum frame with an engine bolted in, telescopic forks up front and a swingarm at the back. Frames are welded and painted. Engines are cast and machined, then fitted with a transmission. Wheels, brakes, wiring and bodywork go on, and the bike is fueled and tested.

  1. Weld the frame

    Steel or aluminum tubes and pressings are welded into the frame, the skeleton that carries the engine, wheels and rider. It includes the steering head for the front forks.

    Goes in
    SteelAluminum

  2. Cast and machine the engine

    Aluminum is poured into molds for the crankcase and cylinder head. A typical bike has one to four cylinders, and a few have more.

    Goes in
    Aluminum

  3. Build the gearbox

    Gears and shafts are fitted in the crankcase to make a manual transmission, commonly five- or six-speed. A chain, belt or driveshaft links the output to the rear wheel.

    Goes in
    Steel

  4. Paint the tank and frame

    Fuel tank, fenders and frame are primed and sprayed, often with several layers of color and clear coat.

    Goes in
    Paint

  5. Drop the engine in

    The engine is lowered into the frame and bolted at several mounting points. Throttle, clutch and exhaust follow.

    Goes in
    Car engine

  6. Fit forks, swingarm and wheels

    Telescopic forks hold the front wheel, and a swingarm with a shock absorber carries the rear one. Wheels arrive with tires already fitted.

    Goes in
    TireBall bearing

  8. Fuel up and run it

    Each bike is filled with oil and fuel, started, and run on rollers before it leaves the line.

    Goes in
    Gasoline
End of the lineMotorcycle

Worth repeating

  • The top four motorcycle producers by volume are Honda, Yamaha, Kawasaki and Suzuki.
  • The 1958 Honda Super Cub became the biggest-selling vehicle of all time, with its 60 millionth unit built in April 2008.

Back to the ground

Follow every input upstream and motorcycle starts as these 29 raw sources.

Crude oilCoalWaterSilica sandNatural rubber latexSulfurIron oreLimestoneAirDolomiteManganese oreNatural gasBauxiteTitanium oreCopper oreCornSugarcaneQuartzTimberRock saltZinc oreLead oreTin oreTronaSilver oreSoybeansRapeseedClaySugar beet

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Sources

Cite this page: "How motorcycles are made." Assembly Line, 2026-11-03. https://assemblyline.org/make/motorcycle

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