In terms of oversizing pistons, and boring, and any other little tricks.

here's what i did to a '95 sport:
bored cyls and fitted xcr440 pistons
bored carbs 1.5mm
cut heads .030"
trail ported cyls
used cdi from a '91 widetrak (had more timing)
used xcr440 sp header and silencer
used large clutches and geared up
used x-tra10 rear torque arm and kimpex gas shocks

it was a fun sled

did that pipe and can come stock on that sled or is that from a 440 XCR also, my sport came with just a pipe no can/pipe.

pipe, can and hanger are from a '97 xcr440sp.
the manifold is stock sport.