How To Make A Can Am Ds 90 Faster – A DIYER'S Guide To Safely

So, your young rider has mastered the Can-Am DS 90. They’ve got the turns down, they’re confident on the trails, but that little four-stroke is starting to feel, well… a little tame. You’ve probably found yourself thinking, “This is a great little quad, but it’s time for a bit more zip.” You’re not alone. It’s a common point every parent reaches when their kid’s skills start to outgrow the machine’s stock performance.

You’ve come to the right place. We promise this guide will give you a clear, safe, and step-by-step roadmap for how to make a can am ds 90 faster. We’re not just going to throw a list of parts at you; we’re going to explain what they do, why they work, and the right order to do things for the best results.

In this complete guide, we’ll walk you through everything from simple, free adjustments you can make in your garage this weekend to the best bolt-on parts for a noticeable power boost. We’ll cover intake, exhaust, tuning, and the essential maintenance that keeps it all running strong. Let’s get wrenching!

Before You Start: Safety and Realistic Expectations

Before we even pick up a wrench, let’s talk shop. The Can-Am DS 90 is a youth ATV, designed with safety as the number one priority. Our goal is to give a growing rider a little more power to keep them engaged, not to turn this quad into a fire-breathing race machine.

Always remember that with more speed comes more responsibility. Ensure your rider always wears a properly fitted helmet, goggles, gloves, and boots. As you increase the quad’s performance, it’s a great time to refresh their understanding of riding etiquette and safety on the trail.

The benefits of how to make a can am ds 90 faster include better throttle response for climbing small hills and more power to pull through sand or mud. The goal is a more capable and fun machine, not a dangerous one. Always supervise your young rider.

The Easiest “Free” Mods to Unleash Hidden Power

Ready for some instant gratification? Can-Am builds these machines with a few built-in limiters to keep them safe for absolute beginners. As your rider’s skills progress, you can safely adjust or remove these. This is one of the best how to make a can am ds 90 faster tips because it costs nothing but a little bit of your time.

Adjusting the Throttle Limiter Screw

This is the simplest mod of all. The DS 90 comes with a throttle limiter screw located on the throttle housing on the handlebars. This screw physically stops the thumb throttle from being pushed all the way, limiting the amount of fuel and air entering the engine.

Locate the screw on the side of the thumb throttle assembly.
Use a screwdriver or the appropriate Allen key to back the screw out.
You can adjust it in small increments, testing after each adjustment, or remove it entirely for full throttle travel.

This single adjustment can make the quad feel like a whole new machine to a young rider, providing a noticeable increase in acceleration and top speed.

Removing the Exhaust Restrictor

Another common limiter is a restrictor plate or washer inside the exhaust header pipe, right where it bolts to the engine cylinder. This small piece is designed to choke the exhaust flow, keeping power levels low.

Removing it allows the engine to breathe out much more freely. You’ll need a basic socket set for this job.

Let the engine cool down completely. Never work on a hot exhaust.
Locate the two nuts holding the exhaust header pipe to the engine.
Carefully remove the nuts and gently pull the pipe away from the engine.
Look inside the end of the pipe. You should see a small plate or washer with a tiny hole in it. That’s the restrictor.
Use a screwdriver or needle-nose pliers to pop it out. It’s usually just press-fit in there.
Re-install the exhaust pipe, ensuring the gasket is in good condition, and tighten the nuts evenly.

With these two free mods done, the DS 90 will already be significantly peppier and more responsive.

A Complete Guide on How to Make a Can Am DS 90 Faster with Bolt-On Upgrades

Once you’ve done the free mods, the next logical step is to improve the engine’s breathing. An engine is essentially an air pump. The more air you can get in and out efficiently, the more power it will make. We’ll tackle this in three stages that work together.

Step 1: Upgrading the Exhaust System

That stock exhaust is quiet and restrictive. An aftermarket performance exhaust is one of the single biggest power-adders for a small engine like this. It uses larger diameter piping and a less restrictive muffler to let exhaust gasses escape faster.

You’ll see a noticeable improvement in throttle response and power across the entire RPM range. Brands like Big Gun or FMF often make systems for youth ATVs. A slip-on muffler is easier to install, but a full system that replaces the header pipe too will yield the best gains.

Step 2: Improving Air Intake and Carburetor Jetting

Now that the engine can breathe out, we need to help it breathe in. A high-flow air filter from a brand like K&N or Twin Air will allow more air into the engine than the stock paper or foam filter.

This next part is critical. More air requires more fuel to maintain the correct air-to-fuel ratio. After installing a performance exhaust and air filter, you must re-jet the carburetor. One of the common problems with how to make a can am ds 90 faster is people skip this step, causing the engine to run “lean” (too much air, not enough fuel), which can lead to overheating and serious engine damage.

You’ll need a carburetor jet kit. These kits come with a variety of main jets and pilot jets in different sizes. You will typically need to go up 2-3 sizes on the main jet from stock. This is one of the how to make a can am ds 90 faster best practices—always tune the fuel to match the airflow.

Step 3: Fine-Tuning with a Performance CDI Box

The CDI (Capacitor Discharge Ignition) box is the brain of your ATV’s ignition system. The stock CDI has a built-in rev limiter to prevent the engine from spinning too fast. After you’ve improved the breathing with an exhaust and intake, the engine will be capable of revving higher than the stock limiter allows.

A performance CDI box, often called a “rev box,” removes this limiter. This allows the engine to rev higher, unlocking more top-end power and speed. This should be the last mod you do in this sequence, as it’s most effective when the engine can already breathe well.

Advanced Tuning: Clutch and Gearing Adjustments

For those who want to fine-tune power delivery, diving into the CVT (Continuously Variable Transmission) is the next frontier. This is a bit more advanced but can make a huge difference in how the quad feels.

Upgrading Rollers and Springs

The DS 90’s CVT uses weighted rollers in the front variator and a large spring in the rear clutch to control how the engine’s power is delivered to the wheels. By changing these components, you can change the engine’s RPM engagement point.

Lighter Rollers: Allow the engine to rev higher before the clutch engages, resulting in much quicker, snappier acceleration from a standstill.
Stiffer Contra Spring: A stiffer spring in the rear clutch helps keep the transmission in a lower “gear” longer, further improving acceleration.

This is a fantastic mod for tight, twisty trails where quick bursts of speed are more important than all-out top end.

Changing Sprockets for Top Speed vs. Acceleration

The final drive on the DS 90 uses a chain and sprockets. You can easily change the gear ratio by swapping the front or rear sprocket.

Smaller Front Sprocket (or Larger Rear): This results in lower gearing. You’ll sacrifice some top speed, but you’ll gain significant low-end torque and acceleration. This is ideal for climbing hills.
Larger Front Sprocket (or Smaller Rear): This gives you higher gearing. Acceleration will be a bit slower, but you’ll gain more top speed on long, flat straights.

Essential Maintenance: The Foundation of Performance (A Care Guide)

All the performance parts in the world won’t help if the basics aren’t covered. A well-maintained quad is a fast quad. This how to make a can am ds 90 faster care guide is non-negotiable.

Clean Air Filter: A dirty air filter is like trying to breathe through a straw. Clean and oil it after every couple of rides, especially in dusty conditions.
Fresh Oil: Clean engine oil lubricates, cools, and cleans. Change it regularly according to the owner’s manual.
Chain and Sprockets: Keep the chain clean, properly tensioned, and lubricated. A tight or dry chain robs power.
Tire Pressure: Check tire pressures before every ride. Low pressure creates drag and slows you down.

Thinking about a sustainable how to make a can am ds 90 faster approach? A properly tuned and maintained engine actually runs more efficiently and cleaner than a neglected one, making regular care an easy win for performance and the environment.

Frequently Asked Questions About Making a Can-Am DS 90 Faster

How fast does a stock Can-Am DS 90 go?

A stock Can-Am DS 90 is typically limited to around 15 mph from the factory. By adjusting the throttle limiter and removing the exhaust restrictor, you can often get it up to the 25-30 mph range.

Is it safe to make a youth ATV faster?

It can be, provided it’s done responsibly. The key is to match the machine’s performance to the rider’s skill level. Always ensure the rider has the proper safety gear and is supervised. The goal is to make the machine more capable, not uncontrollably fast.

Do I need to do all these mods at once?

No, and it’s better if you don’t. Start with the free mods. See how the rider handles the new power. Then, if you decide to upgrade parts, it’s best to do the exhaust, air filter, and carburetor jetting at the same time as they all work together as a system.

What is the best first performance part to buy?

After doing the free mods, a full performance exhaust system is the best “bang for your buck” upgrade. It provides the most noticeable performance increase, but remember you must re-jet the carburetor to support it.

There you have it—a complete roadmap to getting more performance out of your Can-Am DS 90. Take your time, do things in the right order, and always put safety first. Now get out there, get your hands dirty, and have some fun on the trails!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.