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2003 Yamaha YZF600R Maintenance Schedule and Service Intervals

Maintenance schedule and service intervals for the 2003 Yamaha YZF600R a.k.a Thundercat

This is the maintenance schedule and associated service intervals for the 2003 Yamaha YZF600R.

2003 Yamaha YZF600R Maintenance Schedule

Below is the maintenance schedule for the 2003 Yamaha YZF600R

The maintenance for the 2003 Yamaha YZF600R is broken into two sections: periodic maintenance for emission control systems, and general maintenance and lubrication.

Periodic Maintenance Emission Control System

No.ItemRoutine 600 mi (1,000 km) or 1 month4000 mi (7000 km) or 6 months8000 mi (13000 km) or 12 months12000 mi (19000 km) or 18 months
16000 mi (25000 km) or 24 months
20000 mi (31000 km) or 30 months
1*Valve clearance• Check and adjust valve clearance when engine is cold.Every 30,000 mi (42,000 km) or 42 months
2Spark plugs• Check condition.
• Adjust gap and clean.
ReplaceReplace
3*Crankcase ventiation system• Check ventilation hose for cracks or damage.
• Replace if necessary.
4*Fuel line• Check fuel hose for cracks or damage.
• Replace if necessary.
5*Fuel filter• Replace every 20,000 mi (31,000 km) or 30 monthsReplace
6*Exhaust system• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
7*Carburetor synchronization • Adjust synchronization of carburetors.
8*Idle speed• Check and adjust engine idle speed.
• Adjust throttle cable free play.
9*Evaporative emission control system**• Check control system for damage.
• Replace if necessary.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

General Maintenance and Lubrication Chart

No.ItemRoutine 600 mi (1,000 km) or 1 month4000 mi (7000 km) or 6 months8000 mi (13000 km) or 12 months12000 mi (19000 km) or 18 months
16000 mi (25000 km) or 24 months
20000 mi (31000 km) or 30 months
1Engine oil • Replace (warm engine before draining).
(See NOTE on page 6-6.)
2*Engine oil filter cartridge• Replace at 600 mi (1,000 km) or 1 month, and thereafter every 8,000 mi (13,000 km) or 12 months.
3*Air filter/surge tank• Clean.
• Replace if necessary.
4*Cooling system• Check hose for cracks or damage.
• Replace if necessary.
• Replace coolant every 24 months.
• Ethylene glycol anti-freeze coolant.
Replace
5*Brake system• Check operation, pad wear, and fluid leakage. ( See NOTE page 6-6.)
• Replace pads if necessary.
6*Clutch• Check operation.
• Correct if necessary.
7*Control meter and cable• Apply chain lube thoroughly.
• Yamaha Chain and Cable Lube or SAE 10W-30 (API SE) motor oil.
8*Swingarm pivot bearing• Check bearing assembly for looseness.
• Moderately repack every 16,000 mi (25,000 km) or 24 months.
• Lithium-soap-based grease.
Repack
9*Rear suspension link pivots• Check operation.
• Apply grease lightly every 16,000 mi (25,000 km) or 24 months.
• Lithium-soap-based grease.
10*Shock absorber assembly• Check operation and for oil leakage.
• Replace if necessary.
11*Front fork• Check operation and leakage.
• Replace if necessary.
12*Steering bearings• Check bearing assembly for looseness.
• Moderately repack every 16,000 mi (25,000 km) or 24 months.
• Lithium-soap-based-grease.
Repack
13Brake and clutch lever pivot shafts• Apply chain lube lightly.
• Lithium-soap-based-grease (all-purpose grease).
14Brake pedal and shift pedal shafts• Appy chain lube lightly.
• Lithium-soap-based-grease (all-purpose grease).
15*Drive chain• Check chain slack/alignment condition.
• Adjust and lubricate chain thoroughly.
• Special O-ring chain lubricant.
Every 600 mi (1,000 km) and after washing the motorcycle or riding in the rain.
16*Wheel bearings• Check bearing for smooth rotation.
17*Sidestand pivot• Check operation and lubricate.
• Apply chain lube lightly.
• Lithium-soap-based-grease (all-purpose grease).
18*Sidestand switch• Check and clean or replace if necessary.
19*Chassis fasteners• Check all chassis fitting and
fasteners.
• Correct if necessary.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

Note: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting form 4,000 mi (7,000 km) or 6 months.

• The air filter needs more frequent service if you are riding in unusually wet or dry areas.

• Hydraulic brake system
– Regularly check and, if necessary, correct the brake fluid level.
– Every two years replace the internal components of the brake master cylinder and caliper cylinder and change the brake fluid.
– Replace the brake hoses every four years, or if cracked or damaged.

• Engine oil type
– Yamalube 4 (20W-40) or engine oil SAE 20W-40 (API SE) for temperatures of 5°C (40°F) of above.
– Yamalube 4 (10W-30) or engine oil SAE 10W-30 (API SE) for temperatures of 15°C (60°F) of above.

About the 2003 Yamaha YZF600R

This 599cc inline-four made 87.4 hp at 11,500 rpm, 44.7 ft.-lb. of torque at 9500 and weighed 453 pounds dry. Though that might seem like too much weight and too little power today’s 600-class standards, the YZF nevertheless clocked a very respectable quarter-mile time—11.33 seconds at 120.78 mph—and registered a measured top speed of 150 mph.

Manual for the 2003 Yamaha YZF600R

2003 Yamaha YZF600R Maintenance schedule screenshot from manual

The above information was gleaned from the owner’s manual for the 2003 Yamaha YZF600R.

You can download it from Yamaha’s website here.