Customer Spotlight: Kyle Rivers’ 1991 Kawasaki KX500 No-Expense-Spared Restomod

Sep 07, 2026

Customer Spotlight: Rivers’ Unbelievable 1991 Kawasaki KX500 No-Expense-Spared Restomod

When it comes to two-stroke legends, few machines command the respect and sheer terror of the Kawasaki KX500. They are brute beasts of a bygone era, and bringing one back to life is always a massive undertaking. But every once in a while, a customer takes a build to an entirely different stratosphere.

Over the fall and winter of 2025, one of our dedicated customers, Rivers, set out to transform a decent, yet tired, 1991 KX500 into a true masterpiece. The result? A jaw-dropping, one-of-a-kind restomod that spared no expense.

The Build Process: From Tear-Down to Triumph

The project began with a complete strip-down of the vintage chassis. The goal was to blend classic KX500 attitude with modern performance and reliability, with every component meticulously restored or upgraded.

The Foundation: Two-Strokes Only Billet Bottom End Package

At the absolute heart of this powerhouse is our complete KX500 Billet Bottom End Package. To ensure this legendary two-stroke powerplant could handle modern demands and aggressive riding, the build features our premium billet components:

Two-Strokes Only Billet Cases: CNC machined from aerospace-grade aluminum for unmatched strength and structural integrity, eliminating common weak points of the stock castings.
Two-Strokes Only 2-Piece Billet Side Cover & Stator Cover: Not only do these provide a clean, factory-works look, but they offer superior durability and easy access for maintenance.

Performance & Aesthetics: No Detail Overlooked

With the bottom end secure, the rest of the build focused on enhancing performance and dialing in the aggressive aesthetic:

Engine: The cylinder was expertly ported, and the crankshaft was balanced by the wizards at TMR (Tom Morgan Racing) to ensure smooth, tractable, yet ferocious power delivery, paired with a Lectron carb for precise fueling.
Chassis: The iconic KX green frame and matching hubs were treated to a vibrant metallic green flake powder coat.
Suspension & Brakes: The bike now benefits from a modern 450 front-end conversion, providing superior handling and stopping power compared to the 90s-era components.

The finished product is an absolute work of art that bridges vintage two-stroke muscle with modern craftsmanship and reliability. This bike is a testament to Rivers' vision and dedication, and we are incredibly proud that our billet package is at its core.