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Yamaha R6 2nd Gen (2003-2004) Maintenance Schedule and Service Intervals

Blue 2004 Yamaha R6

This is the maintenance schedule and associated service intervals for the 2003-2004 Yamaha R6 2nd gen, formally known as the Yamaha YZF-R6.

The 2003 model got fuel injection, and a little later got radial brakes (in 2005, which we consider separately). Like other models in the R6 series, the 2003-2004 Yamaha R6 2nd gen is a track motorcycle that isn’t too compromised for road riding.

The main changes for the 2nd gen model year were the addition of fuel injection and fully-adjustable 43mm conventional forks.

The 2005 Yamaha R6 Anniversary edition got some minor updates, but the real updates came with the 3rd Gen Yamaha R6 in 2006.

2003 Yamaha YZF-R6
2003 Yamaha R6 red

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Yamaha R6 2nd Gen Maintenance Schedule

Below is the maintenance schedule for the 2003-2004 Yamaha R6 2nd Gen.

The maintenance for the Yamaha R6 2nd Gen is broken into two sections: periodic maintenance for emission control systems, and general maintenance and lubrication.

Notes on reading this maintenance schedule

  • Items marked with an asterisk (*): Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service
  • From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 month

Further notes

  • Clean/lubricate chain every 500 mi (800 km) and after washing the motorcycle or riding in the rain
  • The air filter needs more frequent service if you are riding in an unusually wet or dry areas
  • Hydraulic brake system
    • After disassembling the brake master cylinder and caliper, always replace the brake fluid. Regularly check the brake fluid level and fill the reservoirs as required
    • Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid
    • Replace the brake hose every four years, or if cracked or damaged.

Periodic Maintenance Emission Control System

Distance (mi, US)60040008000120001600020000
Distance (km, Eur/Aus)100010000200003000040000
ItemTime (mon)1612182430
Fuel line•Check fuel hoses for cracks or damage
•Replace if necessary
Spark plugs•Check condition
•Adjust gap and clean
•Replace periodically (R)
RR
Valve clearance•Check and adjust valve clearance (ever 26.6K miles or 40K km)
Crankcase breather system•Check breather hose for cracks or damage
•Replace if necessary
Electronic fuel injection•Check and adjust engine idle speed and synchronization
Exhaust system•Check for leakage
•Tighten if necessary
•Replace gasket(s) if necessary
Evaporative emission control system (For California only)•Check control system for damage
•Replace if necessary
Air induction system•Check the air cut valve and reed valve, and hose for damage
•Replace any damaged parts.

General Maintenance and Lubrication Chart

Distance (mi, US)60040008000120001600020000
Distance (km, Eur/Aus)100010000200003000040000
ItemTime (mon)1612182430
Air filter element• Check condition and damage.
• Replace if necessary.
Clutch• Check operation.
• Adjust or replace cable.
Front brake• Check operation, fluid level, and for fluid leakage.
• Replace brake pads if necessary.
Rear brake• Check operation, fluid level, and for fluid leakage.
• Replace brake pads if necessary.
Brake hoses• Check for cracks or damage.
• Replace (every 4 years)
Wheels• Check runout and for damage.
• Replace if necessary.
Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
Wheel bearings• Check bearings for smooth operation.
• Replace if necessary.
Swingarm pivot bearings• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease.
Repack
Drive chain• Check chain slack/ alignment and condition.
• Adjust and lubricate chain thoroughly.
Steering bearings• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease as scheduled
Repack
Chassis fasteners• Check all chassis fitting and fasteners.
• Correct if necessary.
Brake and clutch lever pivot shafts• Apply lithium-soap-based grease lightly.
Brake and shift pedal pivot shafts• Apply lithium-soap-based grease lightly.
Sidestand pivot• Check operation.
• Apply lithium-soap-based grease lightly.
Sidestand switch• Check operation and replace if necessary.
Front fork• Check operation and for oil leakage.
• Replace if necessary.
Shock absorber assembly• Check operation and for oil leakage.
• Replace if necessary.
Rear suspension link pivots• Check operation.
• Correct if necessary.
Engine oil• Change (warm engine before draining)
Engine oil filter cartridge• Replace.
Cooling system• Check hoses for cracks or damage.
• Replace if necessary.
• Change with ethylene glycol-based coolant every 24 months. Change
Control cables• Apply cable lubricant thoroughly
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.
Maintenance schedule for 2003-2004 Yamaha R6

About the 2003-2004 Yamaha R6 2nd Gen

The 2nd Gen Yamaha R6 gets fuel injection and a re-tune. It has more mid-range than previous models and it spins up more quickly, too.

The Yamaha YZF-R6’s 16v, DOHC motor is just as frenetic as ever, but around town there’s loads more flexibility than before.

The 2nd gen Yamaha R6 gets improved suspension, though the real improvements came in 2005 with upside-down forks.

Manual for the 2003-2004 Yamaha R6

2005 Yamaha YZF-R6 Maintenance schedule screenshot from manual

The above information was gleaned from the owner’s manual for the 2004 Yamaha YZF-R6. It’s identical to the previous year.

You can download it from Yamaha’s website here.

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