Hello,
Could you possibly compare if the .lcf files are the same in both cases (v9.2 vs. v8.5).
I suspect there might be a gap between two sections. The binary file cannot "skip" the gaps then its size may be much bigger in comparison to e.g. s19 or elf file.
Another option is to enable Linker option "generate multiple binary files". in this case if there is a address gap between two sections a separate binary file for each section is created.
Can you post your .lcf + .map files for both cases (v9.2 vs. v8.5) for further analysis if the suggestion above does not help.
Thanks
Stan