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2021-2026 Honda CR500 Drop-In Engine Package

Sale price $7,500.00

Shipping calculated at checkout

Pipe & Silencer
Keihin PWK38 & Throttle Assembly
TSO Air Box Assembly
Spend $250 to get free shipping

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Drop pure open-class two-stroke power directly into your modern aluminum chassis. This complete, ready-to-run CR500 power plant is engineered specifically for the 2021–2026 Honda CRF450R and CRF250R frames.

Built from the ground up as a brand-new unit, this engine features our proprietary billet bottom end cases and custom billet cylinder head. Designed for zero-compromise fitment, it bolts straight into your modern chassis with no frame cutting or welding required.

What’s Included with the Engine Kit:

  1. Complete Turnkey CR500 Engine: Fully assembled with proprietary billet cases, billet cylinder head, exhaust flange, and reeds/intake manifold
  2. Complete Chassis Mount Set: Direct bolt-in engine mounting brackets and hardware
  3. Exhaust Mounts: Pipe hanger brackets
  4. Fuel System Conversion: Modern EFI tank fuel pump delete block-off kit
  5. Cooling Hardware: Custom cooling lines and weld-on radiator crossover fittings

What’s Needed to Complete the Build:

To get your swap fired up and running, you will need to source or supply the following components:

  1. Exhaust: 1990–2001 CR500 expansion chamber pipe, 1990–2001 CR500 silencer with mounting hardware, pipe-to-silencer rubber seal, and CR500 pipe spring kit
  2. Fuel & Intake: CR500 carburetor, throttle assembly, throttle cable, and TSO Airbox Conversion Kit
  3. Electronics: Complete CR500 ignition system (MSV Racing ignition paired with an OEM CDI recommended), NGK spark plug cap, and a universal kill switch (such as Tusk)
  4. Controls: CR500 kickstarter lever, and CR500 shift lever (stock CRF250R/450R shift lever also works)

Fitment:

  • 2021–2026 Honda CRF450R / CRF450RX / CRF450RWE
  • 2022–2026 Honda CRF250R / CRF250RX

Compatibility

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Year Make Model

Customer Reviews

Overall rating: 4.9 / 5 from 58 reviews.

Customer photo review of 1987-2004 Kawasaki KX500 Shift Fork Kit

Shipping was fast, the product is great! When you could still buy the shift forks from Kawasaki they came out of spec :-( These are in spec and far better quality than Kawi's forks. They are in the bike and vastly improved the shifting on this KX500 BEAST!!! Thanks Luke!

1987-2004 Kawasaki KX500 Shift Fork Kit

Customer photo review of 2017-2025 Honda CRF450r/CRF250r Billet Gas Cap

Unfortunately, the gas cap got scratched during shipping, but after a few friendly emails, the problem was resolved perfectly for both sides. Friendly service, quick solutions, absolutely reliable Top-notch shop👍

2017-2025 Honda CRF450r/CRF250r Billet Gas Cap

Customer photo review of 1988-2004 KX500 Billet Engine Cases

Amazing!!! Luke is so helpful. These cases are amazing and a direct fit of my old cases. All parts are equally made and not one is below my standards

1988-2004 KX500 Billet Engine Cases

The best machined pieces I have ever seen. I have wanted a two piece KX500 billet side cover for a long time and can't wait to install it. So trick!

1986-2004 KX500 Two-Piece Billet Side Cover

Very quick shipping, and super pleased with the quality of this stator cover! The anodized black blends nicely with the satin black powder coat on my KX500 engine.

1983+ KX500 Billet Stator Cover- Kawasaki Logo

Quality parts!!! Very happy with what I received for the money!! Fit and finish is top tier. Also happy to support a company who is helping keep these two strokes alive! I will be back for more parts soon!

Billet Rear Silencer Bracket | KX500 & KX250

Bearings were a perfect fit. A couple of shaft bearings were on back order, which I reicieved shortly after a majority of my orders arrived. Quality of everything is immaculate I would certainly do business with Luke again. I honestly wish I could have purchased the billet cases for my kx500af build after seeing the precision on the covers and head. Highly recommend TSO

1986-2004 Kawasaki KX500 Complete Engine Bearing Kit

I ordered the case saver for my 98 kx250, the price of the TSO case saver was very close to the same as the original kawasaki one. The difference is huge, The TSO case saver is made of stainless steel for extra strength and great looks. Shipping and customer service was very fast and included mounting hardware. First time I ordered from TSO, but it won't be my last. Thanks TSO for offering a quality part and great customer service!

1992–2004 KX250 Case Saver| 316 Stainless Steel

So the cylinder head is immaculate and performs perfectly with the decompression valve. Much much easier to start this 500cc 2 stroke. I just wish I the decompression valve was coming off the side instead of straight out the top. Decompression valve creates interference taking out the spark plug when everything is mounted and the bike is together. Purchased a new wrench to remove the spark plug and all is ok. Overall happy 😁

1989-2004 Kawasaki KX500 Billet Cylinder Head Kit

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