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2024-2026 Kawasaki KX500 Drop-in Engine Package

Sale price $7,500.00

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Drop unmatched open-class two-stroke power directly into Kawasaki's newest generation aluminum chassis. This complete, ready-to-run KX500 power plant is engineered specifically to drop directly into the 2024–2026 KX450 and 2025–2026 KX250 frames.

Built from the ground up as a brand-new unit around our proprietary billet engine cases, this engine delivers modern engineering and optimized transfer porting while eliminating the need for any frame modifications. The built-in hydraulic clutch slave cylinder hooks straight into your stock 2024+ KX master cylinder and line. Engineered for a direct fit with no frame cutting, heating, or welding required.

What’s Included with the Engine Kit:

  1. Complete Turnkey KX500 Engine: Fully assembled with proprietary billet center cases, optimized transfer ports, cylinder head, exhaust flange, and reeds/intake manifold
  2. Hydraulic Clutch Integration: Integrated billet clutch slave cylinder (plumbs directly to your stock modern KX master cylinder and hydraulic line)
  3. Chassis Mount Set: Direct bolt-in cylinder head stays, upper engine mounts, and mounting hardware
  4. Case Protection: 316 stainless steel case saver
  5. Exhaust Mounts: Expansion chamber and silencer hanger brackets
  6. Fuel System Conversion: Modern EFI tank fuel pump delete block-off kit
  7. Cooling Hardware: Complete conversion cooling line kit
  8. Electronics Mounting: Rubber CDI mount

What’s Needed to Complete the Build:

To get your conversion finished and running, you will need to source or supply the following components:

  1. Exhaust: KX500 conversion expansion chamber (Hygge Performance KX500 conversion pipe recommended) and silencer
  2. Intake & Rear Suspension: TSO Conversion Intake Boot and TSO Billet Conversion Rear Shock Body (required for intake bell clearance in the modern chassis)
  3. Fuel & Carburetion: KX500 carburetor, throttle assembly, and throttle cable
  4. Electronics: KX500 ignition system, coil, spark plug cap, and kill switch
  5. Controls: KX500 kickstarter lever and shift lever (KX450/KX250 works)

Fitment:

  • 2024–2026 Kawasaki KX450 / KX450X
  • 2025–2026 Kawasaki KX250 / KX250X

Compatibility

Fetching compatibility details...

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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