How To Make A Can-Am Ds 90 Faster – Your Complete Guide To Safe

There’s nothing like seeing the grin on your young rider’s face as they zip around the track or trail on their Can-Am DS 90. It’s a fantastic little ATV, built tough and designed to be a perfect entry point into the world of off-roading. But if your rider is starting to get more confident, you’ve probably heard the familiar request: “Can we make it go faster?”

You’ve noticed they’re holding the throttle wide open everywhere, and the little engine is giving all it’s got. You agree it’s time for a bit more power, but you want to do it safely and correctly. That’s where we come in. We promise this comprehensive guide will walk you through everything you need to know.

This is your ultimate how to make a can-am ds 90 faster guide. We’ll cover simple, free de-restrictions you can do in an afternoon, move on to bolt-on upgrades like exhaust and intake, and even touch on advanced mods for when you’re ready to get serious. Let’s get wrenching and unlock that hidden potential.

Understanding the DS 90’s Built-in Limiters (And Why They’re There)

Before we start removing parts, it’s crucial to understand why your Can-Am DS 90 feels a bit sluggish from the factory. BRP (Bombardier Recreational Products) installs several limiters on these machines for one very important reason: safety.

These youth ATVs are designed for brand-new, inexperienced riders. The limiters keep the speed and power manageable, allowing kids to build skills and confidence without the machine getting away from them. But as skills progress, those safety nets can become a performance bottleneck.

The two primary restrictions you’ll find are:

The Throttle Limiter Screw: A simple screw that physically prevents the throttle lever from being pushed all the way.
The CVT Variator Restrictor: A metal spacer or ring inside the continuously variable transmission (CVT) that stops the belt from riding to the top of the pulleys, effectively locking it out of its “highest gear.”

Addressing these two factory limiters is the most significant first step in your quest of how to make a Can-Am DS 90 faster.

The First & Easiest Step: How to Make a Can-Am DS 90 Faster by Removing Restrictions

Ready for the biggest bang-for-your-buck upgrade? This one costs you nothing but a little bit of time in the garage. Removing the factory restrictions will instantly unleash a surprising amount of power and speed. This is where everyone should start.

Adjusting the Throttle Limiter Screw

This is the simplest adjustment you can make. The throttle limiter is a long screw located on the throttle housing on the handlebars. When screwed in, it physically stops the thumb throttle from being fully depressed.

Locate the screw on the throttle assembly. There will be a lock nut holding it in place.
Use a wrench to loosen the lock nut (typically 10mm).
Use a screwdriver to back the screw out. You can back it out completely or just a little at a time to gradually increase the available power as your rider gets more comfortable.
Once you’re happy with the position, tighten the lock nut back down to secure the screw.

Pro Tip: Don’t just remove it entirely at first. Back it out in stages over several rides to allow your child to safely adapt to the increased throttle response.

Removing the CVT Variator Restrictor

This is the real game-changer. The CVT restrictor is a spacer ring on the front pulley boss (the variator). Its job is to keep the two halves of the pulley from closing completely, which prevents the drive belt from reaching its highest ratio.

Tools You’ll Need:

8mm & 10mm sockets
Ratchet and extension
Impact wrench (highly recommended) or a variator holding tool
17mm or 19mm deep socket (check your model year)

Step-by-Step Process:

Remove the CVT Cover: Use your 8mm socket to remove all the bolts holding the plastic or metal CVT cover on the left side of the engine. You may need to gently tap it with a rubber mallet to break the seal.
Access the Variator Nut: You’ll now see the front pulley (the variator) and the rear pulley (the clutch). The nut holding the variator on is what you need to remove.
Remove the Nut: This is where an impact wrench makes life easy. A few zaps and the nut will spin right off. If you don’t have one, you’ll need a special variator holding tool (spanner wrench) to keep the pulley from turning while you break the nut loose with a breaker bar.
Slide the Variator Off: Carefully remove the outer pulley face. Then, slide the entire variator assembly off the crankshaft splines. Be mindful of the belt.
Find and Remove the Restrictor: Look at the metal sleeve (the boss) in the center of the variator. You will see a thick metal spacer ring around it. That’s your target. Simply slide it off and put it in your spare parts drawer.
Reassembly: Clean any dust out of the CVT case. Slide the variator back on, making sure the splines engage. Put the belt back in place, reinstall the outer pulley face and the nut. Torque the nut to the manufacturer’s specification (usually around 35-40 ft-lbs). If using an impact, give it a few good ugga-duggas, but don’t go crazy.
Test: Reinstall the CVT cover and start the ATV on a stand. Gently give it some throttle to ensure the belt is seated correctly and everything operates smoothly before letting your rider take off.

Just by removing this restrictor, you can see a top speed increase from a stock ~15 mph to nearly 25-30 mph. This is the most crucial part of any how to make a can-am ds 90 faster care guide.

Level 2 Upgrades: Improving Airflow & Exhaust

Once you’ve de-restricted the DS 90, the next logical step is to help the engine breathe better. Think of an engine as a big air pump. The more air you can get in and the more exhaust you can get out, the more power it will make. This is where you start seeing the real benefits of how to make a can-am ds 90 faster.

Upgrading the Air Filter & Intake

The stock air filter is designed to be quiet and adequate for the restricted engine. Swapping it for a high-flow performance filter is an easy and inexpensive upgrade.

Look for a quality foam filter from a brand like Uni Filter or a pleated filter from K&N. These allow more air to enter the engine while still providing excellent filtration. Just remember, a high-flow filter requires more frequent cleaning and oiling to protect your engine.

Crucial Note: Changing the airflow this much will likely make your engine run lean (too much air, not enough fuel). You must adjust the carburetor jetting to compensate. We’ll cover that in the next section.

Installing a Performance Exhaust

The stock exhaust is heavy, restrictive, and designed for quiet operation. An aftermarket performance exhaust from a company like FMF or Big Gun will provide a much more direct path for exhaust gasses to escape.

The benefits are threefold: a noticeable increase in horsepower and throttle response, a significant weight reduction, and a much better sound (which kids love). This is one of the most popular how to make a can-am ds 90 faster tips for a reason.

Just like with the intake, a performance exhaust will require you to re-jet the carburetor to ensure the engine gets the extra fuel it needs to match the extra airflow.

Dialing It In: Carburetor Tuning for Optimal Performance

This section is where many DIYers get intimidated, but it’s absolutely critical. One of the most common problems with how to make a can-am ds 90 faster is bolting on parts without tuning the fuel delivery to match. This leads to poor performance and can even cause catastrophic engine damage.

When you add a high-flow intake or exhaust, you lean out the air/fuel mixture. Running too lean causes the engine to run very hot, which can melt a piston. Re-jetting the carburetor simply means swapping out tiny brass jets inside the carb to allow more fuel to flow.

The main components you’ll adjust are:

The Main Jet: This controls the fuel mixture from about 3/4 to full throttle. After an intake/exhaust mod, you will almost certainly need to go up a few sizes on your main jet.
The Pilot Jet: This controls the fuel mixture at idle and just off-idle.
The Needle Clip: This fine-tunes the mixture in the midrange (1/4 to 3/4 throttle). Lowering the clip (raising the needle) richens the mixture.

A good starting point is to buy a jet kit for your DS 90. After installing your mods, start with a main jet that is 2-3 sizes larger than stock. A quick way to check your mixture is to do a “plug chop.” Ride the ATV at full throttle for a short distance, hit the kill switch, and coast to a stop. Pull the spark plug and look at the color of the ceramic insulator. You’re looking for a nice, cardboard-brown color. White or gray is too lean (danger!), and black or sooty is too rich.

Advanced Mods: Gearing, Clutches, and Big Bore Kits

If you’ve done all the above and still want more, it’s time to get into more serious engine work. These mods require more mechanical skill and investment.

Changing Sprockets (Gearing)

You can change your final drive gearing to prioritize either acceleration or top speed.

Better Acceleration: Install a smaller front sprocket or a larger rear sprocket. This is great for tight trails and getting out of corners faster.
Higher Top Speed: Install a larger front sprocket or a smaller rear sprocket. This is ideal for open fields or long, flat straights.

Performance Clutch & Variator Kits

Aftermarket clutch kits often include stiffer springs that cause the clutch to engage at a higher RPM, launching the ATV harder off the line. Performance variators have differently angled ramps that allow the belt to shift more aggressively, improving acceleration.

The Big Bore Kit

This is the ultimate power-adder. A big bore kit replaces the stock cylinder and piston with larger components, increasing the engine’s displacement (e.g., from 90cc to 110cc). This provides a massive jump in torque and horsepower but is also the most complex and expensive modification, often best left to a professional mechanic.

Safety First: Best Practices & Care Guide for a Faster ATV

More speed demands more responsibility. As you follow this guide on how to make a can-am ds 90 faster, you must also upgrade your approach to safety and maintenance. These are the how to make a can-am ds 90 faster best practices.

Upgrade Safety Gear: If your rider is going faster, their gear needs to be up to the task. Ensure they have a high-quality, properly fitting helmet, goggles, gloves, boots, and a chest protector.

Check Your Brakes: More go requires more whoa. Inspect the brake pads and fluid regularly. Ensure the brakes are properly adjusted and can lock up the wheels if needed.

Increased Maintenance: A modified engine is working harder. You should check your chain tension, tire pressure, and oil level before every single ride. This is the core of a good how to make a can-am ds 90 faster care guide.

Finally, consider the concept of sustainable how to make a can-am ds 90 faster. Proper tuning isn’t just about peak power; it’s about reliability. A well-tuned engine that isn’t running lean will last longer. A properly jetted carb also ensures the fuel is burned more completely, which is a more efficient and eco-friendly how to make a can-am ds 90 faster approach.

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

What is the single best mod to make a DS 90 faster?

Without a doubt, the best and most effective first modification is removing the CVT variator restrictor ring. It costs nothing and provides the most significant gain in top speed, instantly transforming the machine.

How fast can a de-restricted Can-Am DS 90 go?

A stock, restricted DS 90 is limited to about 15 mph. After removing the CVT and throttle restrictions, you can expect a top speed in the range of 25-30 mph, depending on rider weight and terrain.

Do I really need to re-jet my carburetor after an exhaust upgrade?

Yes, 100%. A performance exhaust allows much more air to flow through the engine. If you don’t add more fuel (by re-jetting) to compensate, the engine will run dangerously lean, which can lead to overheating and severe engine damage like a melted piston.

Are these modifications safe for my child?

This depends entirely on your child’s skill level, maturity, and riding environment. The key is to introduce speed and power gradually. Start by backing out the throttle screw a little at a time. Always ensure they are riding under supervision and wearing all appropriate safety gear.

Unlocking the performance of your Can-Am DS 90 is a rewarding project that can grow with your young rider. By starting with the basic restrictions and moving up methodically, you can safely add excitement and longevity to their off-road adventures.

Remember to always prioritize safety, perform regular maintenance, and teach responsible riding habits. Now get out in the garage, wrench safely, and get ready to see an even bigger smile on their face!

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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.