What about "Hercules"? My DS loved that movie, plus it's very funny (w/ the two sidekicks for Hades, I forget their names!). Plus, the main character is a real he-man, the villain is male, the "coach" is male, etc. There is a curvaceous girl in distress....
What about "Mulan"? The main character is a girl, but she dresses as a boy and is not "princess-ey" at all. Lots of male characters in that one.
This is probably too old for your son now but my family, boys especially, love the Disney musical "Newsies" which has a nearly all boy cast. It has Ann Margaret in it and was probably Christian Bale's first big role. Every time they watch it they just love it. I think it is rated PG.
Meet the Robinsons
Toy Story 1 &2
Lion King 1, 1.5, &2
Barnyard! (I think we watched this one 100 times!)
I'd check out the library and see what he's in to- it's a free risk then!