Posted April 17, 2006

Ask the Experts

I race in the production class and have developed a few cracks in my frame. I want to brace the frame but I'm not sure what the rules are. Can you help me?
Daniel Hall
Bancroft, Wisconsin

Doug Morris: We have talked to a number of racers in the pits who race new high-performance four-stroke ATVs that have experienced similar problems. Here's what the rules say:

According to Chapter 11- ATVs in the AMA Sports 2005 Rules, you have two possible situations. If you are racing in any of the very popular production or stock classes, here is how the rule reads: ``15. ATV OEM frames in the stock and production classes may have material added for strength. These changes shall not affect frame geometry.''

If you are racing in any of the modified classes and don’t plan to ever enter a production or stock class, you can add to, or modify or brace, the frame anyway you want.

Many racers will just take their ATV to a qualified welder to weld up the crack. There is another way: an engineered gusset kit designed specifically to address your problem. We called Mike Walsh, owner of Walsh Race Craft, to find out more.

Mike, why should someone use a gusset kit engineered for their specific model of ATV?

We have done our research at the track, and have years of experience, so we know what works and what doesn’t.

The gusset kit is a wise investment for anyone racing motocross. In motocross situations, your chassis will undergo a serious amount of flexing and fatigue. A stock chassis is made from mild steel, which isn't nearly as strong and flexible as 4130 chromoly. You will eventually break the stock chassis and need to replace it.

Are your kits made of the same type of metal as the frames?

All plates and tubes featured in the Walsh Race Craft gusset kit are made from 4130 chromoly material and all pieces in the gusset kit were designed to add a significant amount of strength to the stock chassis where it is most needed, which in turn will help the chassis withstand the abuse that it faces in everyday racing and riding.

By adding the gusset kit to the chassis, you won't need to replace your chassis nearly as soon as you would without it.

Does one kit fit all frames?

No. Walsh Race Craft gusset kits are specifically engineered for the following models: TRX450R, YFZ450, LTZ400 and KFX400.

For the YFZ450, you can choose to add four-mount upper A-arm mounts, six-point sub-frame tabs and/or pro-peg nerf bar mounts. For the LTZ400 and KFX400, you can add pro-peg mounts, and for the TRX450R there are no add-ons.

What tips do you have for installing your gusset kit?

You can take it to a local machine shop with a certified welder to have it installed. If you have the proper equipment and skills, you can do it yourself. But don’t attempt to weld your frame if you don’t know what you are doing. If you run into any problems, we will be here to assist you.

The other option is to ship the frame to Walsh Race Craft for professional installation. We can also powder coat your frame in a number of popular colors.

Doug Morris is director of the All-Terrain Vehicle Association and is well-schooled in the rules governing ATV racing. Mike Walsh is a professional ATV racer and owner of Walsh Race Craft. You can contact him at (860) 889-5482, or by e-mail at sales@wracing.com.

© 2006, All Terrain Vehicle Association