[mcclelland32]

Here are some head pics. Exhaust ports are silmilar size. Intake side is way bigger. And the cam has quite a bit more lift. But I dont have and piston to valve interference issues due to the slightly larger combustion chamber.

Thanks for posting the pictures. Does the head have any marking?

 

[southcaroilnawilliams]

Here are some head pics. Exhaust ports are silmilar size. Intake side is way bigger. And the cam has quite a bit more lift. But I dont have and piston to valve interference issues due to the slightly larger combustion chamber.

Thanks for posting the pictures. Does the head have any marking?

No markings. I looked right away after getting it. Just fired it up for the first time. It fired right up. Gotta go and buy a new chain tomorrow. The one I have is pressed on and I don't have a master link so I am just going to go ahead and get a better one while I am at it. It revs so fast I thought I had a issue with the jetting but realized it was hitting the rev limiter. Took a minute to get the idle adjusted and to be honest I think the cable he sent is a little long in my book at least in the adjustment. I think I might pull the carb back out tomorrow and mess with the cable. I am also going to recheck the valve lash and make sure it is still where it needs to be. I will post up some pics tomorrow of the process.

 

[mcclelland32]

So how did you fix the thrust cover for the camshaft? What do you plan on doing with the stock airbox and variator?

 

[southcaroilnawilliams]

Here is what you have to do to the trust. Just measure, scribe and grind it down and file it flat. Doesn't have to be perfect. Just get it as close as possible. had to make a gasket for it as well. No biggie.

 

[southcaroilnawilliams]

Here is how to change the rear sprocket. Take off the back right wheel hub, rear caliper and get a rubber mallet to beat the axle back. I had to grind the three locating tabs off the sprocket hub for that gear to work. Night and day difference. It is a 33 tooth. Stock front. I think i had to take 2 links out of the stock chain. Did not have a good x ring chain in stock at the local stealer. Gonna order one.

 

[southcaroilnawilliams]

For the chain tensioner i just drilled out the center of that one to the stock bolt size. Used the stock bolt, made a spacer out of a piece of tubing i had laying around and had to cut the end off of the stud that the roller rides on. That was my solution you may come up with something different. As long as it is close to the stock dimension you should be good. That was my take on it. Someone else may do it different.

 

[mcclelland32]

For the chain tensioner i just drilled out the center of that one to the stock bolt size. Used the stock bolt, made a spacer out of a piece of tubing i had laying around and had to cut the end off of the stud that the roller rides on. That was my solution you may come up with something different. As long as it is close to the stock dimension you should be good. That was my take on it. Someone else may do it different.

I ended up doing the same as you except I used the spacer maximum rpm provided that went between the springs. Just had to drill it out and cut it. The sprocket is aluminum, right? Did you lose a lot of the bottom end?

 

[southcaroilnawilliams]

For the chain tensioner i just drilled out the center of that one to the stock bolt size. Used the stock bolt, made a spacer out of a piece of tubing i had laying around and had to cut the end off of the stud that the roller rides on. That was my solution you may come up with something different. As long as it is close to the stock dimension you should be good. That was my take on it. Someone else may do it different.

I ended up doing the same as you except I used the spacer maximum rpm provided that went between the springs. Just had to drill it out and cut it. The sprocket is aluminum, right? Did you lose a lot of the bottom end?

It actually feels like it picked up on the bottom end. It is probably due to the increased torque. Top end is greatly affected. It feels way faster and you can throttle on oversteer the machine like a big boy quad!

 

[southcaroilnawilliams]

I still have not found the optimal spark plug and jetting combo yet. I an currently running the stock plug for the trx90. Which is a colder plug. At first I was chasing a supposedly rich condition and i found out that the stock plug was fouled giving me false readings. I believe it was fouled from the get go from the float hanging up on the stock carb and head combo. Which is why I dismantled the quad from the get go. I currently have a 56 pilot and a 85 main. It is reading lean. I think I am going to put the 90 main back in and see what she says. The idle circuit seems good. However I have to note that I still don't have the air cleaner installed so that will richen it up when I put it on. Justin forgot to send it with my other stuff. That is the main reason I have not done any extensive testing as my tune is likely to change. I am also running 100 octane gas as well.

 

[mcclelland32]

I still have not found the optimal spark plug and jetting combo yet. I an currently running the stock plug for the trx90. Which is a colder plug. At first I was chasing a supposedly rich condition and i found out that the stock plug was fouled giving me false readings. I believe it was fouled from the get go from the float hanging up on the stock carb and head combo. Which is why I dismantled the quad from the get go. I currently have a 56 pilot and a 85 main. It is reading lean. I think I am going to put the 90 main back in and see what she says. The idle circuit seems good. However I have to note that I still don't have the air cleaner installed so that will richen it up when I put it on. Justin forgot to send it with my other stuff. That is the main reason I have not done any extensive testing as my tune is likely to change. I am also running 100 octane gas as well.

Are you running a colder plug for a specific reason? If so, what? I'm waiting on the big valve head and intake for the pe20mm carb to get here. What was your fix for the carb to fit under the tank? Raise the tank or did you dent the bottom of the tank so the cable does not bind?

I ordered a 17t steel sprocket for the front. Stock is 16t so I'm interested to see what that will do with the big valve head. part number is JTF259.17, paid $8.49 on amazon.

 

[southcaroilnawilliams]

I just dented the tank with a hammer. Don't think you could space it that high. My reasoning for that plug was it was readily available at the local auto parts store. The local dealership was closed and that was the only one in the group of heat ranges they had. I ordered some others as well but it seemed to work ok. I will do some testing when my air filter and the other plugs arrive this week. Thanks for the heads up on the front sprocket.

 

[southcaroilnawilliams]

I just dented the tank with a hammer. Don't think you could space it that high. My reasoning for that plug was it was readily available at the local auto parts store. The local dealership was closed and that was the only one in the group of heat ranges they had. I ordered some others as well but it seemed to work ok. I will do some testing when my air filter and the other plugs arrive this week. Thanks for the heads up on the front sprocket.

By the way I think it is the wrong heat range plug and I am at the 100 main and it still seems lean. Idle is rich still. I have the 56 idle going to snag the plugs up and some various jets Friday and get some testing done weather permitting. Every main increase thus far I feel has yielded more power so I think I am headed in the right direction.

 

[mcclelland32]

The 17t sprocket fits just fine. It clears the case saver and you do not need to add any links to the chain. Just slide the rear axle a little forward. I added one inner link and another master link just to see what that did to the tension of the chain and you have to slide the axle back at little more than half way. I didn't like the fact you have 3" or more of the tensioner bolt sticking out the back so I'm going to remove the extra links and slide the axle forward.

 

[mcclelland32]

I just dented the tank with a hammer. Don't think you could space it that high. My reasoning for that plug was it was readily available at the local auto parts store. The local dealership was closed and that was the only one in the group of heat ranges they had. I ordered some others as well but it seemed to work ok. I will do some testing when my air filter and the other plugs arrive this week. Thanks for the heads up on the front sprocket.

By the way I think it is the wrong heat range plug and I am at the 100 main and it still seems lean. Idle is rich still. I have the 56 idle going to snag the plugs up and some various jets Friday and get some testing done weather permitting. Every main increase thus far I feel has yielded more power so I think I am headed in the right direction.

Can you post some pictures of what the carb looks like on the quad? I'm curious to see the angle the intake puts the carb at and how long it is. Is the choke a pain in the ass to reach now?

 

[southcaroilnawilliams]

Here is where the carb comes out. No problems and works better than I originally thought.

 

[mcclelland32]

See you got an air filter now... How is it running? Hey since the air box is gone where do you have the breather tube running to? Or is it even on. Smell like oil? I was thinking and I might try to see if it will work. Get a 12 way carb kit so I can rotate the carb straight and modify the airbox to accept the 46mm OD of the pe20mm carb.

 

[southcaroilnawilliams]

See you got an air filter now... How is it running? Hey since the air box is gone where do you have the breather tube running to? Or is it even on. Smell like oil? I was thinking and I might try to see if it will work. Get a 12 way carb kit so I can rotate the carb straight and modify the airbox to accept the 46mm OD of the pe20mm carb.

I just ran the breather hose up the frame like it was. I am going to put a small filter on it but don't think it is needed. But I will put one on it anyways. I didn't try and get the air box back in for the simple fact it is just more parts to take if you have any maintenance work. Less is more in my book! Don't plan on sinking it in a mud pit. Still have not been able to really test it yet rain every weekend since Christmas and my work schedule. Plus the fact I want to get some more plugs and jets which I am about to head out to his morning and scoop that stuff up. But it is definitely a major improvement just don't know how major yet. That's the thing about custom setups there is no magic combination for everything. Just a lot of trial and error.

 

[southcaroilnawilliams]

Ok so after a day of tuning and disappointment I have learned a few things. If you have a pe20 carb and it constantly shows a rich condition no matter what you do as far as jetting you likely have a defective carb. I double triple checked timing, compression, spark, multiple heat range plugs, and jets. I tuned and tuned and tuned and finally called justin. Told him what was going on and that I was so frustrated that I ordered a stock head gasket and was ready to scrap the whole project all together and he stated that he had a customer with the same scenario and that it wound up being a defective carb. He said the guy sent his back and he tried it on a good running bike he had that ran the pe20 and he had the same issues with it. I could get mine to run ok on the top end but the idle circuit I could not get running right unless the air screw was almost ready to fall out and the idle was a good bit higher than it should. Even then it still wanted to hunt at idle. I am hopefull this is the issue as I am almost certain it is. The carbs are mass produced cast aluminum and I am sure the qc is not as stringent as the space program. My local shop said he had a bad fcr carb out of the box but had never seen a pe series bad out of the box. Keihin is still one of the best makers out there but once in a while I guess you get a lemon. I got one. Just my luck. The bike only has maybe 2 hrs on it thus far. The only reason I did the conversion so soon was because the float on the stock carb got hung up after the first 30 min of operation. Had to take the whole bike apart to get to it and decided to go ahead and do the conversion. So I guess I have a carburetor curse with this quad. Hopefully my luck changes!

 

[GregNZ]

Hey there, it's been interesting following your posts re the ds90 upgrade. I'm doing the same as you have although I have only just installed it and not started the tuning process . I'm based in New Zealand and Cam-am is a rare brand let alone getting up grade bits for one. I got the Hetrick power up kit for my boys bike. Apart from having to beat the **** out of the tank so the carb fits all the other stuff fits great. I found a way to use the RPM chain tensioner properly, I fabricated a small bracket out of steel, drilled hole in it and bolted it to the original tensioner mount, spot wielded each end to secure, then drilled another hole at only end of bracket for the RPM unit to fit straight onto, fits and works mint! I'll post a pic when I return hm in a few weeks time.
Is the bigger head a must?? It's the only thing I have not done yet.
Cheers
Greg

 

[mcclelland32]

Ok so after a day of tuning and disappointment I have learned a few things. If you have a pe20 carb and it constantly shows a rich condition no matter what you do as far as jetting you likely have a defective carb. I double triple checked timing, compression, spark, multiple heat range plugs, and jets. I tuned and tuned and tuned and finally called justin. Told him what was going on and that I was so frustrated that I ordered a stock head gasket and was ready to scrap the whole project all together and he stated that he had a customer with the same scenario and that it wound up being a defective carb. He said the guy sent his back and he tried it on a good running bike he had that ran the pe20 and he had the same issues with it. I could get mine to run ok on the top end but the idle circuit I could not get running right unless the air screw was almost ready to fall out and the idle was a good bit higher than it should. Even then it still wanted to hunt at idle. I am hopefull this is the issue as I am almost certain it is. The carbs are mass produced cast aluminum and I am sure the qc is not as stringent as the space program. My local shop said he had a bad fcr carb out of the box but had never seen a pe series bad out of the box. Keihin is still one of the best makers out there but once in a while I guess you get a lemon. I got one. Just my luck. The bike only has maybe 2 hrs on it thus far. The only reason I did the conversion so soon was because the float on the stock carb got hung up after the first 30 min of operation. Had to take the whole bike apart to get to it and decided to go ahead and do the conversion. So I guess I have a carburetor curse with this quad. Hopefully my luck changes!

Oh man that sucks ass!! I probably would have thrown the carb into the wall of my garage. I'm assuming Justin is sending you another carb, right? Hope the next carb is good to you!