There have been a number of requests regarding information on how to use the OEM mag (cast) wheels on the 1600. The purpose of this thread is to provide the detailed information we have in one thread.

It seems that some people have success using other methods. I suspect this may be due to changes from year to year that are not readily apparant until one tries to interchange parts from one year onto another. Don't assume that the following intructions will work for your application ... caveat emptor.

Doc

Motostar installed 04 wheels on his 99 and this is the info that he provided.

There are two bearings in the cush drive hub the big bearing needs to be changed not the needle bearing; use all 04 collars see list below. Some guys talked about a different spacer for the rotor side, I used my 99 ones and the wheel turns smoothly and the belt aligns centre, I didn't notice any difference between the spacers other than the top diameter to cover more of the oil seal.

Go to [url=http://www.starmotorcycles.com/star/parts/home.aspx][Star Parts[/url] and print the 04 and 99 wheel diagrams with the parts numbers so that you can see exactly which parts fit together; however, be aware that the 04 diagram is misleading as some of the bearings are not shown on the correct side of the wheel as installed.


Rear Wheel

Parts from the 99 to 2003 that can be reused on the 2004

905602033900 SPACER
2 of 933063043700 BEARING(3BC)
6 of 4WM253640000 DAMPER
4WM253760000 COLLAR, WHEEL retail
90387202X900 COLLAR(3BC)

Parts from the 99 to 2003 that could be reused on the 2004 wheels if they are not damaged in removal

931063000400 OIL SEAL,DD-TYPE - could be reused if they are not damaged in removal 99 to 2003 on the 2004 wheels
5 of 956171263000 BOLT, STUD - could be reused if they are not damaged in removal 99 to 2003 on the 2004 wheels

Parts that need to be purchased

5VN2533800WN CAST WHEEL, REAR
933173359000 BEARING
931062800100 OIL SEAL
2 of 990095250000 CIRCLIP
5VN253660000 HUB
933173267700 BEARING,CYLINDRICAL
5VN253830000 COLLAR, WHEEL
934503501500 CIRCLIP,INNER
939000003000 VALVE,RIM
903872001200 COLLAR
6 of 4WM-25364-00-00 DAMPER WHEEL HUB
5VN254700000 PULLEY, DRIVEN (70T)


Front Wheel

Parts from the 99 to 2003 that can be reused on the 2004

The outer wheel bearing collars (or spacers) are the exact same and can be used from the 99 to 2003 on the 2004 wheels.

903872208J00 COLLAR (center spacer between the two bearings)

Parts from the 99 to 2003 that could be reused on the 2004 wheels if they are not damaged in removal

2 of 933060042000 BEARING
2 of 931062804300 OIL SEAL

Parts that need to be purchased

5VN2516800WN FRONT CAST WHEEL
939000003000 VALVE,RIM

This was obtained from a post by Grey on how to swap the 1700 mag wheels onto a 1600 (years not provided):

The 04 brake rotor side dust seal #5(04 diagram 93106-28001-00 OIL SEAL)is different, which means you need the spacer #30(04 diagram 90387-20012-00 COLLAR) for it. Some people have reused their 03 spacers(#32 03 diagram 90387-202X9-00 COLLAR) and that is great but Yamaha designed it diffently for a reason so why mess with it replace it.

The cush drive side had quite a few changes to the bearings, they got rid of the two bearing #4(03 diagram 93306-00416-00 BEARING B6004RS) setup in the wheel and went with a needle bearing instead #4(04 diagram 93317-33590-00 BEARING), Then they added the big spacer #14(04 diagram 5VN-25383-00-00 COLLAR,WHEEL) which slides into the needle bearing. This now is the spacer for the wheel cush drive setup unlike the 03, this means you will need to change out the bearing in the cush drive #9(03 diagram 93306-20551-00 BEARING)with the 04 Bearing #10 (04 diagram 93306-30437-00 BEARING) and no longer need the spacer #13(03 diagram 4WM-25377-00-00 COLLAR, WHEEL)