Well, the show and the toys were well known for inconsistances. There were vehicles that were named wrong, people who's names changed and masks that changed shapes. I'll try to list all of these, if you know of one let me know and I'll add it. :)
Ace Riker was also called Ace Striker.
Firefly was called Dragonfly.
Hurricane was introduced as the Nightstalker.
Stinger was called Scorpian.
The Ricochete mask was called Boomerang mask.
Powerhouse mask was called Sampson.
There were also some repaints. This was usually in the action figure, and Matt Tracker was the biggest victum of this. They are listed below.
|Matt Trakker-Thunderhawk||Was repainted into the Jungle Challange colors|
|Matt Tracker-Rhino||Was repainted into the Coastal Patrol colors|
|Dusty Hayes-Gator||Was repainted into the Billboard Blast colors|
|Alex Sector-Boulder Hill||Was repainted into the Collector colors|
|Bruce Sato-Rhino||Was Repainted into the Rescue Mission colors|
|Miles Mayhem-Switchblade||Was repainted into the Venoms Revenge colors|
|Sly Rax-Piranha||Was repainted into the Pitstop Catapult colors|
The masks also changed shapes from time to time in the toy line. All of the early masks poped up later with added plastic. the easy answer is that they didn't pass safty standards, but some of the later masks were even smaller. So I don't know why they did it, but they did. Below is an example that should show what I'm talking about.
There were some vehicle variations also. These seemed to be trying to bring the toys into line with the show. the only example I have right now is the laser cannon on the condor. The first release had a flat looking cannon, while the later releases had a rounded looking cannon that matched the show better. If you know of more let me know! :)
The Gator picture in the 1985 catalogue has the Spectum mask shown with it...And upside down at that.