As I said before you need better fuel, more octane, its really that simple! Simply jetting the sled way up will for sure keep your dcs light off but the engine will also lose power because its jetted way too rich. The reason the light is not coming on is because your cooling off the piston,pipe with excess fuel, and with excess fuel is a rich mixture, lower power output.
If you dont think your losing power take the sled to a dyno, hook it up and start changing jets, keep adding fuel and see what happens to the power curve. I dont think you really understand what specific mods do to what certain parts of the engine, as in port timing, head set up, etc. and your basing all this rhetoric posting on someone elses suggestions without having a working knowledge of the engine. I am refering to your comment about "adding more jet adds octane to a motor", and it ran "hotter then heck" with big jets in it.
As far as testing goes, you have to test set ups and changes all in the same conditions, this means various set ups /changes on the same day,temp etc, not a 1 time ride per year as your doing coming up from mississippi.
Thanx for the offer to better help me with doing 02 srx engines for people but I dont seem to have any problems with them, nor do the people that have gotten them done, I appreciate the offer though. They just simply use the right fuel and add booster for cheap insurance against lousy gas found at todays pumps. I think in the long run really the answer may simply be for you to sell the ported topend and remove the clutching set up and return the sled to all stock, sounds like youd have far less trouble with it.
Good luck Tom, be sure to post your pics of the piston wash when you get to that point in your research, see ya later.