I need to reduce the weight of the DS650. With the motor pulled, the ATV still weighs more than an oem trx250r.

See pic of frame here:
DS650 Frame

The diameter of the tubing is large. The wall thickness of the tubing is large.

Any ideas on how to significantly reduce weight by modifiying the existing frame? Drill holes? Reduce wall thickness somehow - special tool; acid? Cutout any unnecessary support tubing?

Would a lonestar non-titanium drag frame accomodate the DS motor? What about an LRD 400EX aluminum frame?

Who does custom frame work that might be able to help?

Thanks,

Scooby

 

You could make the rear sub frame out of aluminum and get the aluminum swingarm used on the 04`s.

I have seen in Dirt Wheels (5+ yrs ago) a Banshee with a completely drilled frame every tube. It looked cool and since it was only used for striaght line sand drags they said it would hold up. Not sure how much they saved couldn`t have been much.

Try places that specialise in sand drags for info on drilling. HTH