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2004 Yamaha YZF600R Maintenance Schedule and Service Intervals

Maintenance schedule and service intervals for the 2004 Yamaha YZF600R a.k.a Thundercat

This is the maintenance schedule and associated service intervals for the 2004 Yamaha YZF600R.

2004 Yamaha YZF600R Maintenance Schedule

Below is the maintenance schedule for the 2004 Yamaha YZF600R

The maintenance for the 2004 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*Fuel line• Check fuel hose for cracks or damage.
• Replace if necessary.
2Fuel filter• Replace.Replace
3Spark plugs• Check condition.
• Adjust gap and clean.
• Replace every 8,000 mi (13,000 km) or 12 months.
ReplaceReplace
4*Valve clearance• Check and adjust valve clearance when engine is cold.Every 26,600 mi (42,000 km)
5*Crankcase breather system• Check breather hose for cracks or damage.
• Replace if necessary.
6*Carburetor synchronization • Adjust synchronization of carburetors.
7*Idle speed• Check and adjust engine idle speed.
8*Exhaust system• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) 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
1*Air filter element• Clean with solvent. (See NOTE.)
• Replace if necessary.
2*Clutch• Check operation.
• Adjust or replace cable.
3*Front brake• Check operation, fluid level, and for fluid leakage. (See NOTE.)
• Replace brake pads if necessary.
4*Rear brake• Check operation, fluid level, and for fluid leakage. (See NOTE.)
• Replace brake pads if necessary.
5*Brake hoses• Check for cracks or damage.
• Replace. (See NOTE.)Every 4 years.
6*Wheels• Check runout and for damage.
• Replace if necesssary.
7*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
8*Wheel bearings• Check bearing for smooth rotation.
• Replace if necessary.
9*Swingarm pivot bearings• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease.
Repack
10Drive chain• Check chain slack/alignment condition.
• Adjust and lubricate chain with a
special O-ring chain lubricant thoroughly.
Every 600 mi (1,000 km) and after washing the motorcycle or riding in the rain.
11*Steering bearings•Check bearing assembly for looseness
•Moderately repack with lithium-soap-based grease.every 16,000 mi (25,000 km) or 24 months.
Repack
12*Chassis fasteners• Check all chassis fitting and fasteners.
• Correct if necessary.
13Brake/clutch lever pivot shafts• Apply lithium-soap-based grease (all-purpose greases) lightly.
14Brake and shift pedal pivot shafts• Apply lithium-soap-based grease (all-purpose greases) lightly.
15Sidestand pivot•Check operation.
• Apply lithium-soap-based grease (all-purpose greases) lightly.
16*Sidestand switch•Check operaton and replace if necessary
17*Front fork•Check operation and for oil leakage
• Replace if necessary.
18*Shock absorber assembly• Check operation and for oil leakage.
• Replace if necessary.
19*Rear suspension link pivots• Apply lithium-soap-based grease lightly.
20Engine oil • Change (warm engine before draining).
21*Engine oil filter cartridge• Replace.
22*Cooling system• Check hoses for cracks and damage.
• Replace if necessary.
• Change with ethylene gylcol anti-freeze coolant every 24 months.Change
23*Control and meter cables• Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly.
24*Throttle grip housing and cable• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.

* 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 from 8,000 mi (13,000 km) or 12 months.

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

● Hydraulic brake service.
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.

About the 2004 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 2004 Yamaha YZF600R

2004 Yamaha YZF600R Maintenance schedule screenshot from manual

The above information was gleaned from the owner’s manual for the 2004 Yamaha YZF600R.

You can download it from Yamaha’s website here.