QUOTE(450RRR @ May 21 2009, 05:37 PM)

you can go up to about 295/310cc (depending on company) with just bore size on their cylinders with no case machining... above that... you need to machine the cases.....
ESR/Duncan/CT, etc...all fine 250r companies.
Greg pretty much sums it up. With a stroker kit, machining the case halves and using the Pro-X or Honda FL400 Pilot cylinder you can get it up to 410cc. The largest bore on the stock cylinder is 265cc. Don't buy the BS marketing of the "310" kits as they are actually only 295cc. Anything over 295cc's without a stroker will require you to machine the engine cases to fit a larger sleeve as well as go with an aftermarket cylinder.
If you want a sweet setup, shoot for a non-stroker 350cc kit with a powervalved aftermarket cylinder. Save yourself some heartache and replace your 2nd gear in the transmission while the cases are apart. It's around $100 and it's always the first thing to give with the big power builds. Also get a 38-39mm flat slide carb to go with it and a good reed cage setup.
Cool heads are good insurance for a big cc build as well. Good luck!
Jared