I wanted the cast wheels on my 2000 R*, so here is what I did and came up with.  I changed out my spoke wheels to the newer '04 and up stock cast wheels.  I also wanted a 32 tooth front pulley, so I changed that out in the process. If you do this conversion on the 03 and later you MUST also change your belt size from the 1 1/2" to the 1 1/4" belt.

I got my front 32 tooth OEM front pulley from www.pinwallcycle.com.  They have very good pricing on salvage parts. The 32 tooth pulley that I got was off of a Warrior.  I don't think it would made a difference as long as it is '04 and up.  They all still fit.

I was able to luck up on a set of complete '06 cast wheels off of a custom build locally.  When I say complete, I mean bearings, seals, spacers and all.  If you are lucky enough to be able to get the wheels this way, you can literally just bolt them on.  You MUST use the stock spacers from the '04 and up on the rear wheel.  You can use your '03 and up spacers on the front.

The front is an easy bolt on, with no issues.  If you want to change you front brake calipers to the 04 and up, you can.  BUT, If you change over the front calipers, you MUST also change over the master cylinder to the 04 and up also.  The reason is, the '04 and up front calipers are 4 piston where as the 03 and later are only 2 piston.

The rear wheel is also just a bolt on.  But, you can use you '03 and later pulley if you want.  There is a little bit more involved with this.  You must change over your cush drive also and change the rear space back to the 03 and later. IF you stay with the 04 and up theme, just bolt up and go.

To change out the belt, you must remove the swing arm.  If you have a very good friend to hold the swing arm, you can do it with out taking everything else loose(shock, dogbones,etc.).  If you have to do this yourself, I highly recommend taking everything off before you pull the swingarm shaft.

* You do not have to have a high skill level to complete this mod, BUT I do highly recommend a bike LIFT vs the bike jack.  If you use a bike jack, take all safety precautions to strap it down!!

If anyone has any questions, feel free to ask. I don't know everything about this, but I did find out a lot about this mod.

Thanks, T

* What I mean by "lift" is a full bike lift. it lifts the whole bike up.  If you have a lift you should also have a "jack" to get each wheel off the lift at a time.  A "jack" is a standard atv/mc floor jack.

 
StonColdStar