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Yamaha YZF600R Thundercat (1996-2007) Maintenance Schedule and Service Intervals

2006-2007 Yamaha YZF600R

This is the maintenance schedule and associated service intervals for the Yamaha YZF600R Thundercat (though it wasn’t called the Thundercat everywhere).

The Yamaha YZF600R was the predecessor to the YZF-R6, which was sold alongside it for a while. The YZF600R was the more comfortable, everyday sports motorcycle — though it was still no slouch with its high-revving 599cc engine that made 75 kW, or 100 hp.

The YZF600R didn’t change in its lifetime other than in external styling and in the seat, and so the maintenance schedule from the latest manual is applicable to all years.

After the YZF600R had its day, it was conceptually replaced by the more upright Yamaha FZ6.

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Yamaha YZF600R Maintenance Schedule

Below is the maintenance schedule for the Yamaha YZF600R.

Things you may need to buy to service your YZF600R

Here’s a few items that you may need to buy to service your Yamaha YZF600R.

Part/consumableYZF600R specification and link
Engine oilYamaha recommends using their own motor oil, which is affordable and good. Yamalube 10W-50 covers a huge range of operating temperatures, from below freezing to above 100 degrees F / 40 degrees C. You can also opt for another name-brand high-grade synthetic like Motul 7100 or Mobil 1 Synthetic.
Oil filterMany Thundercat owners use aftermarket filters with a nut on the end like the Hiflofiltro HF303RC for easy replacement
Spark plugsYou need four spark plugs for the YZF600R, NGK CR9E.
Air filterA popular aftermarket alternative is the K&N air filter YA-6096.
Chain lubricantA really popular chain lubricant that’s low-mess and highly effective is Motul chain paste.
Cable lubricantKeeping good clutch action depends on having a well-lubricated chain. You can use engine oil, but Protect All Cable Life is an affordable and well-used staple of maintenance.
Mechanical greaseIt’s important to grease moving parts, like the sidestand and sometimes bearings, to keep them from getting notchy or seizing. Valvoline moly-fortified grease meets a lot of needs.
YZF600R maintenance parts

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

Maintenance notes:

  • Yamaha recommends you only service the chain, change the oil, and grease major lube points, and send everything else to a dealer (not likely!)
  • The air filter needs more frequent service if you are riding in unusually wet or dry areas.
  • In more recent years, Yamaha recommends you change the air filter rather than clean it with compressed air.
  • Service intervals
    • The mile metrics come from the US service manuals, and the KM metrics from the European ones.
    • After the end of the maintenance schedule, keep going in the pattern established here.
  • 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.

Periodic Maintenance Emission Control System

Every (mi)60040008000120001600020000
Every (km)100010000200003000040000
Every (months)1612182430
Fuel line• Check fuel hose for cracks or damage.
• Replace if necessary.
Fuel filter• Replace (R)R
Spark plugs• Check condition.
• Adjust gap and clean.
• Replace (R) periodically with NGK CR9E
RR
Valve clearance• Check and adjust valve clearance when engine is cold.Every 26,600 mi (42,000 km)
Crankcase breather system• Check breather hose for cracks or damage.
• Replace if necessary.
Carburetor synchronization • Adjust synchronization of carburetors.
Idle speed• Check and adjust engine idle speed.
Exhaust system• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
Evaporative emission control system
(CA only)
• Check control system for damage.
• Replace if necessary.
Maintenance schedule — YZF600R Thundercat

General Maintenance and Lubrication Chart

Every (mi)60040008000120001600020000
Every (km)100010000200003000040000
Air filter element• Clean with solvent.
• Replace if necessary (YA-6096)
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 break 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 condition.
• Adjust and lubricate chain (Motul chain paste)
Every 600 mi (1,000 km) and after washing the motorcycle or riding in the rain.
Steering bearings• Check bearing assembly for looseness.
• Moderately repack with lithium-soap-based grease periodically or every 24 months
Repack
Chassis fasteners• Check all chassis fitting and fasteners.
• Correct if necessary.
Brake/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• Apply lithium-soap-based grease lightly.
Engine oil • Change (warm engine before draining) with Yamalube 10W-40
Engine oil filter cartridge• Replace (HF303RC)
Cooling system• Check hoses for cracks and damage.
• Replace if necessary.
• Change with ethylene gylcol pre-mix coolant every 24 months.Change
Front and rear brake switches• Check operation.
Control and meter cables• Apply Yamaha chain and cable lube or engine oil 10W-30 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.
Lights, signals and switches• Check operation
• Adjust headlight beam.
General maintenance schedule — YZF600R Thundercat

About the Yamaha YZF600R

The YZF-600R is a sports bike with amazing performance – in tune with the everyday needs of the real world.

The 600R is a perfectly balanced, versatile middleweight sport machine that recognizes that in this imperfect world, you can’t live your whole life out on the track.

That’s not to say that the 600R doesn’t still rail through hairpins with the best of them: the liquid-cooled, 16-valve Genesis in-line 4-stroke engine gives you low- and mid-range performance that packs a race-sized wallop.

But for everyday riding, a wide, plush seat, slightly rearset footpegs and a broader, taller windshield and fairing also deliver a highly practical ride.

Manual for the Yamaha YZF600R

2006-2007 Yamaha YZF600R Maintenance schedule screenshot from manual

The above information was gleaned from the owner’s manual for the 2006-2007 Yamaha YZF600R. It’s the same as other years.

You can download it from Yamaha’s website here.

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