Just another product offered by TSO that makes my bike build better. Looks great and will survive the Southern Arizona desert.
1989-2001 Honda CR500 Direct Bolt-On Performance Cylinder
Sale price
$1,199.00
Shipping calculated at checkout
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 Two-Strokes Only, 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 improved performance 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 improved reliability without the need for extensive porting work.
What's Included & Optional Upgrades
Included in the box:
1. All-New CR500 Replacement Cylinder (STD 89 mm Bore)
2. Top end gasket set
Optional Add-Ons (Select from the drop-down menu):
- Piston Kit: Complete drop-in piston kit ready for installation.
- TSO Billet Cylinder Head: Maximize cooling and performance with our custom billet head.
- TSO Billet Reed Spacer: Optimize intake tract volume and throttle response.
- TSO Billet Exhaust Flange: A heavy-duty, leak-free upgrade over the stock cast flange.
Key Features
- 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, while retaining a good useable powerband.
- 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.
- 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.
- 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.
- 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
| Feature | Specification |
| Fitment | 1989–2001 Honda CR500 |
| Bore Size | 89.00mm |
| Material | All-Aluminum Cast |
| Bore Coating | Nikasil Plated |
| Porting Style | Optimized Factory-Plus |
| Exhaust Layout | Improved Single Bridged |
| Thermal Management | Upgraded Exhaust Duct Cooling |
| Modifications Required | None (Direct Bolt-On) |
| Compatibility |
Accepts all OEM & Aftermarket Top-End Components, replaces Honda 12100-ML3-680 DESIGNED TO WORK WITH WOSSNER AND WISECO FORGED PISTONS Wiseco: 871M08900 Wossner: 8229DA |
Compatibility
Fetching compatibility details...
| Year | Make | Model |
|---|---|---|
Customer Reviews
Overall rating: 4.9 / 5 from 66 reviews.
Part seems to be machined well.
Perfect solution for replacement of OEM. Allows for smoother and more positive engagement.
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!
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👍
Perfect product... Perfect all around transaction!!
Great solution for KX500 airbox seal issue. Very nice product.
1989-2004 Kawasaki KX500 Billet Air Filter Sealing Kit (1989-2004)
Everything I have received from TSO has been excellent, I was excited to see TSO had the pressure plate because they was the only ones , thanks for amazing products and service
1988-2004 Kawasaki KX500 88-91 KX250 KDX250 Clutch Pressure Plate 13187-1060
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
Very well made pipe fits good have not been riding yet so don’t know if it leaks out two stroke oil like the stock one does we will see when it gets cool out for riding
My first order and I'm very happy!
Killer cover!!! Great fitment
Fitted without issue and looks the part, just need to upgrade other parts to look as nice.
Great communication they help me out when I question about how curtain things go I highly recommend them
It fits perfectly, and its even better than ever.
1989-2004 Kawasaki KX500 Center Power Valve assembly| 12023-1058 & 12005-1111
Awesome custom part! Finally someone makes good parts for my 89 Suzuki lt250r. Great customer service.
Exelent product
Everything looks great ! Quick turn around very pleased ✌️
Great billet part for my KX500. The machining quality is amazing. Much better than the stick plastic part.
1989-2004 Kawasaki KX500 Billet Air Filter Sealing Kit (1989-2004)
Great product
Part works great!
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!
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.
Two strokes only is the place to get hard to find KX500 engine parts. The best machined parts I have ever seen.
1989-2004 Kawasaki KX500 Center Power Valve assembly| 12023-1058 & 12005-1111
Great quality, exceptional service
Fine quality piece too bad it's hidden away from the eyes 😎
👍
head look great and quality is superb
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!
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
great shipping
Very thankful people out there make this stuff!!
Haven't installed these parts yet but the maching and quality looks better than OEM. Looking forward on trying out their other specialized parts offered.
Quality piece, may buy another. Can't wait for LT500 heads to become available. Will buy 2 when that day comes.
Finally a great after market head for the lt 250! Fits, looks and runs great!
My suspension guy loved the shock, which is high praise. He has seen a lot of custom suspension components in his career.
👍
KX500 Engine Rebuild Bolt Kit for Kawasaki KX 500 Specbolt Nickel Wurks Ti Look
Quality piece. I should have bought 2.
Great outlet, must have if using the billet clutch side cover on a steel frame bike!
Great quality part
