1989-2001 Honda CR500 Direct Bolt-On Performance Cylinder

The wait is almost over. This is exactly what the big bore community has been needing. Stop paying huge amounts of money for worn-out used cylinders that require extensive repair work, or shelling out a fortune for NOS units that still leave you stuck with factory stock performance.

Exclusive to TwoStrokesOnly.com, this is the very first entirely new, direct-replacement stock bore cylinder of its kind to hit the CR500 market. We kept the proven characteristics of the original Honda design and strategically modernized the rest to unleash its true potential. No hacking, no case grinding, no headaches—just a massive performance leap and unquestionable reliability in a true bolt-on package.

Whether you are rebuilding a blown top end or looking for the ultimate big-bore upgrade, this cylinder delivers modernized airflow and rugged durability without the need for custom fabrication.

What's Included & Optional Upgrades

Included in the box:

(1) All-New CR500 Replacement Cylinder (Stock Bore)

Optional Add-Ons (Select from the drop-down menu):

1. Piston Kit: Complete drop-in piston kit ready for installation.
2. Top End Gasket Set: Everything you need to seal up your fresh top end.
3. TSO Billet Cylinder Head: Maximize cooling and performance with our custom billet head.
4. TSO Billet Reed Spacer: Optimize intake tract volume and throttle response.
5. TSO Billet Exhaust Flange: A heavy-duty, leak-free upgrade over the stock cast flange.

Key Features

1. Strategic Porting Evolution: We kept what actually worked from the original factory porting and made critical improvements where they were needed most. The result is an incredibly reliable, highly versatile cylinder that puts out more power than any hand-ported OEM unit on the market.
2. Improved Exhaust & Thermal Management: Built around an improved single bridged exhaust port, this design maximizes flow while offering superior piston and ring support. We also engineered improved cooling at the top of the exhaust port duct to relieve thermal stress on the bridge, actively preventing the cracking commonly seen in bridged all-aluminum cylinders like the CR250.
3. Rugged Construction: Cast from high-quality aluminum and finished with a low-friction Nikasil plated bore for unmatched heat dissipation, oil retention, and maximum longevity.
4. True Direct Bolt-On: Drops right onto your factory bottom end. Zero crazy case modifications, machining, or bike alterations are required. Bolt it down and ride.
5. Universal Compatibility: Build it your way. This unit is 100% compatible with all original (OEM) and aftermarket reeds, pipe flanges, cylinder heads, pistons, and top-end gaskets.

Technical Specifications

Bring your CR500 into the modern era. Add to cart to experience the ultimate upgrade for your 500 top end.