Is your little ripper’s Can-Am DS 90 feeling a bit sluggish? Maybe it’s hard to start, bogs down when they hit the throttle, or just doesn’t have the “get up and go” it used to. You’re not alone—it’s a common story for these otherwise fantastic youth ATVs.
I promise you, there’s a simple, effective solution that can completely transform that little quad. A well-chosen can am ds 90 carburetor upgrade is one of the best bang-for-your-buck mods you can do, waking up the engine and making it more reliable and fun to ride.
In this complete guide from us here at FatBoysOffroad, we’ll walk you through everything. We’ll cover the real-world benefits, how to choose the right carb, a full step-by-step installation process, and the secrets to tuning it for perfect performance. Let’s get those hands dirty!
Why Bother with a Can-Am DS 90 Carburetor Upgrade? (The Real Benefits)
The stock carburetor on the DS 90 is designed to meet strict emissions standards and keep the power output very mild for new riders. While great for day one, it quickly becomes a bottleneck that holds the engine back.
Upgrading unlocks that choked-up potential. Here are the tangible benefits of can am ds 90 carburetor upgrade you can expect.
- Improved Throttle Response: The most immediate change you’ll feel. The engine will rev quicker and feel much snappier, eliminating that frustrating bog or hesitation off the line.
- Increased Power: A larger, better-designed carburetor allows more air and fuel into the engine. More air and fuel, when mixed correctly, equals more power—perfect for tackling small hills or keeping up on the trail.
- Easier Starting: Many aftermarket carbs have better choke circuits and are less finicky than the stock units. This means less time trying to get the quad running and more time riding.
- Greater Tunability: The stock carb offers very limited adjustment. An aftermarket carb opens up a world of tuning with replaceable pilot and main jets, allowing you to dial in the fuel mixture perfectly for your climate, elevation, or other performance mods like a pipe or air filter.
Choosing the Right Carburetor: Your Upgrade Options
Walking into the world of carburetors can feel overwhelming, but for the DS 90, it’s pretty straightforward. The key is not to go too big. An oversized carb will hurt performance, making the ATV run worse than it did with the stock one.
Understanding Carburetor Sizing
Carburetors are measured in millimeters (mm), referring to the diameter of the venturi (the narrowest point inside). For a stock or lightly modified DS 90 engine, a 19mm to 22mm carburetor is the sweet spot. A 20mm is often the perfect starting point.
Going bigger, like to a 24mm or 26mm, is only recommended if you’ve done significant engine work, like a big bore kit. For most riders, a 20mm will provide the best balance of power and rideability.
Popular Choices and What to Look For
You’ll find many options, from genuine Japanese carbs to more affordable clones. Genuine Mikuni (like a VM20) or Keihin (like a PE20) are top-tier but come at a higher price. Many high-quality clones perform exceptionally well for a fraction of the cost.
Here are some crucial can am ds 90 carburetor upgrade tips when shopping:
- Look for a Kit: The best value is often a kit that includes the carburetor, a matching intake manifold, a new throttle cable, and a pod-style air filter. This saves you the headache of sourcing parts individually.
- Check the Intake Style: Ensure the carburetor has the right mounting style. Most upgrades for the DS 90 use a “spigot mount” that clamps into a rubber intake manifold boot.
- Jet Availability: Make sure you can easily buy different size jets for the carb you choose. Tuning is everything, and you will likely need to swap jets to get it running perfectly.
The Essential Toolkit: Gearing Up for the Job
You don’t need a professional shop to do this job. With a basic set of tools and a little patience, you can knock this out in an afternoon. Here’s what you should have ready:
- A good metric socket set (especially 8mm, 10mm, 12mm)
- A set of metric combination wrenches
- Phillips and flathead screwdrivers in various sizes
- Pliers (needle-nose and standard)
- A clean rag or paper towels
- A can of carburetor cleaner
- A catch pan for any spilled fuel
How to Can Am DS 90 Carburetor Upgrade: A Step-by-Step Guide
Alright, let’s get to the fun part. This is your complete can am ds 90 carburetor upgrade guide. Take your time, stay organized, and remember that safety is always priority one.
H3: Safety First: Prep Your Workspace
Before you turn a single wrench, make sure you’re working safely. Find a well-ventilated area (like an open garage or outdoors) since you’ll be dealing with gasoline. Ensure the engine is cool to the touch. It’s also a good practice to disconnect the negative terminal on the battery.
Step 1: Remove the Seat and Plastics
To get clear access to the carburetor, you’ll need to remove the seat and likely the side plastics. This is usually just a few 8mm or 10mm bolts. Keep your bolts organized in a magnetic tray so you don’t lose them.
Step 2: Disconnect and Remove the Old Carburetor
The stock carb is sandwiched between the airbox and the engine. Follow these steps carefully:
- Turn off the fuel petcock. It’s located on the side of the fuel tank.
- Loosen the clamp holding the airbox boot to the back of the carburetor and pull the boot off.
- Place a rag under the carb’s float bowl and carefully loosen the drain screw to empty any fuel. Then, disconnect the fuel line from the carb inlet.
- Unscrew the cap on top of the carburetor. This will allow you to pull the entire throttle slide and needle assembly out. Set it aside.
- Finally, loosen the clamp on the engine-side intake manifold and wiggle the carburetor free. It might be a tight fit, but it will come out.
Step 3: Install the New Intake Manifold
Your upgrade kit likely came with a new intake manifold. Unbolt the old one from the cylinder head (usually two nuts or bolts). Make sure the gasket surface is clean before installing the new manifold with its new gasket. Don’t overtighten the bolts—just snug them up.
Step 4: Prep and Mount the New Carburetor
Before installing the new carb, it’s smart to open the float bowl and check which size jets are installed. Write them down for future reference. Now, slide the new carb into the new intake manifold and tighten the clamp. Make sure it’s seated all the way in.
Step 5: Connect Everything Up
You’re on the home stretch!
- Connect your new throttle cable to the new carb’s slide and screw the cap on.
- Route and connect the fuel line to the new carb’s fuel inlet.
- Attach your new pod air filter directly to the back of the carburetor and tighten its clamp.
- Turn the fuel petcock back on and check for any leaks.
Fine-Tuning Your New Carb: The Secret to Peak Performance
Simply installing the carb is only half the battle. Now you have to tune it. This process is what separates a decent upgrade from a great one. These are the can am ds 90 carburetor upgrade best practices for getting it right.
Reading the Spark Plug
The spark plug is your window into the engine. After running the quad for a bit, pull the plug and inspect the ceramic insulator. A light, coffee-brown color is perfect. White or ashy means you’re running too lean (not enough fuel), which can damage the engine. Black and sooty means you’re too rich (too much fuel), which fouls plugs and wastes gas.
Adjusting the Idle and Air/Fuel Screw
First, get the quad to idle. Use the large idle speed screw to set a steady idle. Next, find the smaller air/fuel mixture screw (often a brass screw near the engine side of the carb). With the engine idling, slowly turn it in or out until you find the point where the idle is highest and smoothest. This primarily affects the idle-to-1/4 throttle range.
Jetting 101: Main and Pilot Jets
This is where the real tuning happens. The pilot jet controls the fuel mixture from idle to about 1/4 throttle. The main jet takes over from about 3/4 to full throttle. If the quad bogs right off idle, you may need a larger pilot jet. If it sputters or loses power at full throttle, your main jet is likely too rich (too big) or too lean (too small).
Make one change at a time and test it. It’s a process of trial and error, but getting it right is incredibly satisfying.
Common Problems with Can Am DS 90 Carburetor Upgrade and How to Fix Them
Even the best mechanics run into snags. Here are some common problems with can am ds 90 carburetor upgrade and their solutions.
- Bogging on Acceleration: This is almost always a jetting issue. If it bogs right off idle, try a larger pilot jet. If it bogs at wide-open throttle, your main jet is likely too small (lean).
- Won’t Idle Properly: Check for vacuum leaks around the intake manifold first by spraying a little carb cleaner at the gaskets while it’s running. If the idle changes, you have a leak. If not, your pilot jet is likely clogged or the wrong size.
- Fuel Leaking from Overflow: This means the float inside the carburetor bowl is stuck or the needle valve isn’t sealing. Gently tap the side of the float bowl with a screwdriver handle. If that doesn’t work, you’ll need to remove the bowl and clean the float needle and seat.
Sustainable and Eco-Friendly Carburetor Upgrade Practices
Being an off-roader means respecting the environment we play in. A sustainable can am ds 90 carburetor upgrade isn’t just possible, it’s responsible. A properly tuned carburetor is far more efficient than a poorly running stock one.
By achieving a clean air-fuel burn, you not only make more power but also reduce unburnt fuel emissions, making it an eco-friendly can am ds 90 carburetor upgrade. Additionally, be sure to dispose of your old carburetor, fluids, and parts responsibly at a local auto parts store or recycling center.
Frequently Asked Questions About the DS 90 Carb Upgrade
Do I need to change my exhaust if I upgrade the carb?
You don’t have to, but the two upgrades work together beautifully. An aftermarket exhaust helps the engine breathe out just as the new carb helps it breathe in. If you do both, you will definitely need to re-jet the carburetor to account for the increased airflow.
What size carburetor is best for a stock DS 90?
For a stock or very lightly modified DS 90, a 19mm or 20mm carburetor is ideal. It provides a significant performance boost without being too large for the engine’s displacement, which maintains good low-end power and throttle response.
How do I know if my jetting is correct?
The best indicators are performance and the spark plug reading. The quad should accelerate smoothly through the entire RPM range with no bogging or sputtering. A clean, tan-colored spark plug after a full-throttle run confirms your main jet is dialed in.
Can I do this upgrade myself with basic tools?
Absolutely. This is a perfect project for a DIY mechanic. As long as you have basic metric hand tools and can follow the steps in this can am ds 90 carburetor upgrade care guide, you can successfully complete this job.
Unlocking the hidden potential in your Can-Am DS 90 with a carburetor upgrade is a rewarding project that pays off every time your kid hits the throttle. It’s about more than just power; it’s about making the quad more reliable, responsive, and ultimately, more fun.
Take your time with the tuning process, as that’s where the magic really happens. Now get out to the garage, get those hands dirty, and give that little ATV the performance it deserves. Ride safe and have a blast!
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