1989-2004 Kawasaki KX500 Complete Billet Drop-in engine
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Stop chasing 30-year-old cast cases and discontinued OEM ghosts. This is the KX500 engine evolved. We’ve taken the raw violence of the "Beast" and stabilized it with modern engineering, producing a zero hour, ready-to-run engine that is lighter, stronger, and built to handle more abuse than Kawasaki ever intended.
This isn't a rebuild. It’s a total reincarnation of the KX500 engine!
Race Proven by the Pros
Our parts aren't just garage-tested; they are race proven. We’ve put our components through the ringer with professional riders—including testing and development with athletes like Ryan Surratt. When you’re putting our parts to the test, you can be confident in them!
The Build List
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Billet Center Cases: CNC-machined from 6061-T6. We eliminated the porosity and structural "soft spots" of the original 1989–2004 cast units. These cases provide a rigid, high-integrity foundation that far exceed the strength and durability of OEM.
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Full Billet Bottom End: Loaded with our heavy-duty internal suite, including our chromoly shift components and an integrated hydraulic clutch system.
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Two-Piece Billet Clutch Cover: The TSO flagship. Inspect or swap your clutch plates in minutes without touching your coolant or the main side case.
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Billet Cylinder Head Kit: High-flow cooling jackets and a reshaped combustion chamber keep your top-end temps consistent and your power delivery crisp. An integrated compression release ensures easy starting.
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TSO High-End Internals: Our engines are sold with completely refurbished internals which include a new crank assembly, all bottom end bearings and seals, all new shift mechanisms, new piston kit, power valve components and much more. Any parts that we do not produce and are not available are high quality refurbished.
Technical Breakdown
| Component | Specification |
| Platform | 1989–2004 KX500 (Direct Fit) |
| Main Cases | TSO CNC 6061-T6 Billet |
| Clutch Access | Quick-Change Two-Piece System |
| Head Kit | Billet w/ Interchangeable Domes |
| Validation | Pro-Rider & Race Tested |
| Origin | Engineered & Built in Oceanside, CA |
Zero Hours. Zero Compromise.
The TSO Billet KX500 is the ultimate solution for riders who want the legendary soul of a big-bore two-stroke without the reliability headaches of decades-old technology. This is the highest-quality KX500 engine on the planet, hand-assembled right here at Two-Strokes Only
Ordering Information
Built to order with custom dome options available. Contact us for current lead times and shipping details.
