[gh500]

ok lets set the record straight
1) lt250's have 2 rod length's 85-86 & 87-92 (128mm)
lt500's 87-90 have 143mm rod
2) a-arms do not interchange 85-92 the 85-86 are the same & 87-90 are the same
3) swing arms interchange 85-90 85-86 had the round carrier 87-90 had the box style & the carrier is the same all the way to 92
4) plastic will interchange 85-90 the 91-92 plastic mounted slightly diffrent bit can be made to work
5) lt250 & lt500 intakes on the 87-90 do not interchange the lt250's have a straight boot the lt500's angle while we are on intakes 87 is a year by it's self it has 5 bolts the hold it & has 8 pedal reed cage the 88-90 are 6 bolt with 6 pedal reeds the reed cages will interchange lt250 & 500
6)power valve actuator is the same but not the rod & the govenor is not the same
7) flywheels are the same lt250 & 500 but the factory stators on the 85-86 dont have the cut out for the counter balance shaft on the 87up but the coils are all the same so you can use you old plate
8) while in ignition cdi boxes lt250 & 500 ARE NOT the same lt250's have 6deg of timing advance from 1200-9000 the 500's have 2 diffrent boxes the 87-88 have 11 deg of advance from 1200-5500 & the 88-90 have 8 deg of advance from 1200-5500
9) front & rear brakes interchange on lt250,lt500,lt230,several others
10) waterpump bearing is the same on the lt250 & 500 also the seal but the impeller's are not the same
11) yes you can use a yz 250 piston to get rid of the thrust washers but you need to deck the cyl 1mm (.040) which advances the port timing good thing on a stock cyl if you have a ported one you better do some math ! & the cyl needs to be 1mm over to start with & the bores go to 3mm over (suzuki size)
also you can get a 69.7mm piston froma polaris watercraft to get 1 more bore after the .080 stock oversize

yes a lt500 motor will fit in a 250 frame with a couple of mods & a custom pipe

if i have missed anything ask & i can tell you i've been working on suzuki quadracers for over 20 years