The Two-Stroke Shop 2-Stroke Shop

TSS500GP and RS500 Conversion Parts (All prices in US$)

TSS500GP Engine Kit
Supply of TSS500GP crankshaft, cylinder, pistons, entire intake and exhaust tract,
TSS Power Valve System, ignition system, straight-cut primary gears

TSS500GP cylinder, monoblock construction, Nikasil plated, curved power-valve slots:

TSS500GP Toroidal Cylinder Head Inserts

TSS500GP Power Valve System, complete

Stainless power-valve shaft assembly spins in SKF needle roller bearings, backed by Viton seals

Electronic servo operation administered by our ECU for precise and rapid rpm-based operation (power-valve timing is fully adjustable via the ECU)

GP-derived curved power-valve slots/blades (these curve with the cylinder wall for the whole width of the exhaust port so as to closely follow the contour of the piston, therefore giving a more effective boost to low-end and midrange performance. This enables the engine to make serious horsepower from as low as 4000rpm.)

TSS 100mm rotor/stator/stator plate/triggers:
(This rotor/stator is necessary for running the 90 degree firing order crankshaft)

100mm rotor, 650 grams
Only 25% of the inertia of the Yamaha RZ/Banshee flywheel = much quicker rev response and much less strain on the ignition side main bearing

Eight-pole stator
A full eight charging coils = plenty of juice for powering street bike electrics

Billet stator plate

Trigger sensors (two required for TSS500GP engine; three required for a triple; four required for a four-cylinder)

Trigger mounts

Ignition coils with plug leads/caps

Regulator

Ignitech RACE ignition system with wiring loom for plug and play conversion of Aprilia RS250 to RS500GP

Wossner forged piston kits, 73mm (piston/rings/pin/clips)

58mm stroke crankshaft, fully-balanced, 180° or 90° firing order

Options:

(1) 180° or 90° firing order, with ball bearing centre mains and TZ-type SKF Explorer outer mains: $750

(2) 180° or 90° firing order, with ball bearing centre mains and NSK maximum-capacity 11-ball bearing mains -type SKF Explorer outer mains: $697

(3): 180° or 90° firing order, with 7-ball bearing mains throughout: $650

V-Force III reed valves, customised RS500GP spec

Pair of Keihin FCR carburettors, 39mm, on racks, ready to install, pre-set jetting

Custom intake manifold rubbers & TSS500GP top end gasket set/ Stud extenders for cylinder assy

Supply of Domino push/pull throttle assembly and throttle cable for FCR carburettors and TSS Autolube oil pump combined

TSS500GP Expansion Chambers, stainless steel with carbon fibre mufflers, complete with all mounts and spigots/mounting springs

Straight-cut primary gears, 2.68:1 ratio (stock is 2.86:1 helical cut) and revised overdrive oil pump drive pinion

RS500GP Conversion Components Retail Pricing (All prices in $USD)
Components	Pricing
TSS500GP Crankshaft, 58mm stroke, fully-balanced, 90 ° or 180° firing order	Options: (1) 180° or 90° firing order, with ball bearing centre mains and TZ-type SKF Explorer outer mains: $750 (2) 180° or 90° firing order, with ball bearing centre mains and NSK maximum-capacity 11-ball bearing mains -type SKF Explorer outer mains: $697 (3): 180° or 90° firing order, with 7-ball bearing mains throughout: $650
TSS500GP cylinder, 73mm bore, all-alloy, Nikasil-plated	$1485
TSS500GP cylinder head	$150
TSS500GP Head Inserts, pair	$180
TSS500GP Power Valve System, complete	$650
Ignitech fully programmable ignition system, RACE, with wiring loom and connectors for fitting to RS250:	$450
TSS 100mm rotor	$95
TSS 100mm stator	$85
TSS CNC stator plate	$87.50
Wossner forged piston kits, 73mm (piston/rings/pin/clips)	$225 each kit
Heavy-duty gearbox bearings kit	$112
Engine torsion bars x 2, with rod ends/adjusters/locknuts/brackets/under-engine bolts, spacers	$95
Full engine oil seal kit	$65
Billet high-flow water pump impeller	$68
RS500 stainless steel 304 shift rod, rod end and shift shaft lever assembly	$45
Intake manifolds, pair	$58.70
VForce III Reed Valve Systems, customized for TSS500GP, pair	$245
TSS500GP top end gasket set inc. o-rings, base gasket, water fitting gaskets	$55
Expansion chamber exhausts, including silencers & RS500GP mounting rubbers	$1150
Keihin FCR carburettors, 39mm, racked up in pairs, pre-jetted	$1175
Air filters, pair	$58
Billet FCR intake trumpets, pair	$120
Straight-cut primary gears, 2.68:1 ratio	$275
Two-stroke oil pump drive gear, designed to mesh with 2.68:1 S/Cut primaries	$50
RS500GP engine mounting cradle, c/w new rear engine mounts and all fasteners	$650
18.6mm offset sprocket, 17T	$38
New rear shock rocker arm , fitted with new bearings/seals and center pivot bush and new stainless steel dogbones x 2 (necessary for pipe clearance)	$287
Total combined parts cost:	$8829


OPTIONS
Race 46 mm core radiator, customized for RS500GP	$750
Hydraulic clutch lever, master cylinder, line and slave cylinder, direct bolt-on	$190
Custom billet bypass thermostat housing with thermostat	$165
Hinson billet clutch basket, inner rotor, pressure plate, 8-plate clutch plates stack, TSS ultra HD clutch springs	$950
Brand new Banshee engine cases	$500

Enquiries: Steve Rothwell
The Two-Stroke Shop
9 Compass Close, Edge Hill
Cairns 4870
Queensland, Australia
Tel. (In Australia): 0427 774 285
Tel. (Outside Australia): +61 427 774 285
Web: http://www.twostrokeshop.com
Email: offbeat@iinet.net.au

TSS500 GP Engine Build TSS supply and preparation of RD/RZ350 YPVS/Banshee engine for 500 conversion and final assembly of complete TSS500GP engine (US$)
Supply of Engine – Crankcases/Gearbox Yamaha RZ engine bottom end supplied by TSS: US$500
Labour Strip and inspect all components. Bead-blast engine cases. Machine top case to accept larger 500 liners, and transfer port-match.
Replace worn/defective gearbox components. Reassemble engine with new gaskets, gearbox bearings, bearings and seals.
Labour: 20 hours @ US$75/hr	US$1500
Parts: New gearbox bearings Engine seals complete Ultra Heavy-Duty clutch springs and plates	Sub-Total: US$455
Total:	US$2455

RS250 to RS500 Conversion Kit Supply of RS250 TO RS500 conversion parts - all prices in USD
RS500 Engine mounting cradle c/w all fasteners
18mm offset sprocket, 16T or 17T
Trimmed rear shock rocker arm, fitted with new bearings/seals and new stainless steel dogbones x 2 (necessary for pipe clearance)

TOTAL:	US$885

TSS RS500GP Bike, Complete (For Road or Race)
Built according to customer's specifications. or owner-built; from 'sleeper' stock-looking rockets to real race track animals. Contact Steve on offbeat@iinet.net.au for pricing, options, lead times. We build bikes for a worldwide customer base and ship them anwhere.
Prices start at US$16500.

Popular race and street mods include HRC RS250R front ends complete, comprising HRC GP bike Showa forks with custom valving and spring rates/ Brembo brakes/ Marchesini wheels 3.75" front rim and 5.85" rear rim. Custom TSS triple clamps and rear brake bracket; steering damper; GP-spec rear shock.

All of the above over-delivers on the promise of a truly lightweight two-stroke road-racer, with levels of dynamic braking and handling ability to embarrass all four-stroke litre-bike jockeys.