2 theories:
1) Jagga set the time capsule so Lion-o would age more so he would be grown.
2) One is a cat and the other is a kitten, they'll never be but so big.
I'm a karate man, see! And a karate man bruises on the inside! They don't show their weakness.
None of the others aged appreciably, either. I vaguely recall (mind, it's been years) that there was a bit of a malfunction with his cryo chamber. Either that, or the other poster is correct and Jagga jiggered it, knowing Lion-O would need his adult strength.
Or heck, maybe the Sword of Omens did it. I mean, it can do everything ELSE! (But only selectively - I just saw the Menace of Hammerhand, and when that big crow stole the sword, Lion-O apparently forgot that he can call it to his hand...)
Agreed, the Sword's abilities do tend to be a little vairable in the first series - but that's still better than the later series, where that catchphrase becomes a complete fix-all!
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