LT250S, I know this is an old thread, but just thought I'd chime in and say what a good looking bike you're building. Wow! My brother has an LT250s that he's going to be building eventually. There are a lot of differences between these and the 230s. A few things that are interesting. While the bottom end is similar, one big difference I noticed is that to engage reverse, the lever has to be pushed backward for reverse on the 250 versus forward on the 230. The 230E for those familiar with them, is similar to the 250s. You have to push the lever backwards for reverse.

The front end of the 250S is actually about as wide as a 250R. It doesn't sit quite as wide stock only because the stock wheels are more inset. The a-arms are actually longer than 250r a-arms if I remember correctly, but the frame isn't as wide.

The wheelbase is also longer than a 230s. I believe the swingarm is longer.

Also, the factory exhaust header pipe is a good pipe - better than a 230. But the muffler is more restrictive. A good exhaust system would be the factory 250s header pipe with a 230 muffler. (No 4 stroke sounds better than a stock 230s IMO.)

Poweroll used to make big bore kits for the 230 and 250S. Their most powerful kit was a 273cc engine with 12.5 -1 compression I think. With the 230S, you had to install a new sleeve. For the 250S, you did not have to do that, so it was much cheaper to do. They could bore the factory sleeve enough.

GrkGuy, as far as the headlight cage, the bolt pattern is the same on the steering stem for the quadracers and quadsports, at least for the 85 and 86 230S (not sure about the 250S or the laer year 230S when they had the fairing around them). The quadsport headlights are not as good. They have plastic lenses which fade, and they are not as bright as the QR headlights. They are also rigid mounted as opposed to the QR lights which "hang" from the cage via ruber mounts which protects them a little from vibrations and jarring. Also, at least the older 230 lights (85 and 86) are not the same shape. They are more square. I know a few people who have upgraded a sport with a QR light. I've never heard of anyone doing the opposite.