2009 Yamaha YZ450F(Z) Owner's Service Manual (P/N 33D-28199-80)

This 230-page PDF is Yamaha's 2010 YZ450F(Z) Owner's Service Manual, identified on the cover as 33D-28199-80 and on the English title page as 33D-28199-80-E0. Coverage is build-specific: model code 33D1 applies to the USA and Canada, 33D2 to Europe, and 33D4 to Australia, New Zealand, and South Africa. The specification tables distinguish the YZ450FZ name used in the USA, Canada, Australia, and New Zealand from YZ450F in Europe and South Africa, then call out market-specific gearing, tires, dimensions, weight, and rear-wheel travel where applicable.

Best suited to technicians and mechanics who already have basic Yamaha motorcycle-service knowledge, this is a workshop-level manual rather than a beginner's maintenance guide. Yamaha specifically cautions inexperienced users against relying on it alone for inspection, adjustment, disassembly, or reassembly.

• Engine teardown and repair: Covers camshaft and timing-chain work, cylinder-head removal, valve and valve-spring inspection, cylinder and piston service, clutch repair, water- and oil-pump service, balancer work, engine removal, crankcase splitting, crankshaft installation, and five-speed transmission, shift-cam, and shift-fork service.
• Fuel-system workshop procedures: Details fuel-tank and pump removal, fuel-hose handling, fuel-pressure testing, injector checks, and throttle-body removal, inspection, and assembly.
• FI and electrical diagnosis: Includes ignition and throttle-position-sensor testing, FI diagnostic mode, sensor and actuator checks, fault-code troubleshooting, fuel-pump diagnosis, component test values, and harness continuity checks.
• Brake, wheel, and chassis repair: Provides wheel-bearing and brake-disc inspection, caliper and master-cylinder disassembly, hydraulic brake bleeding, steering service, swingarm and linkage work, and rear-shock removal and inspection.
• Fork and suspension service: Covers front-fork removal and disassembly, damper and base-valve work, oil-seal replacement, oil-level setup, reassembly checks, and compression/rebound adjustment.
• Maintenance and reference data: Supplies race-based maintenance schedules, pre-operation checks, valve-clearance adjustment, ignition-timing checks, cooling and lubrication service, torque tables, capacities, wear limits, electrical specifications, and detailed cable, hose, brake-line, and wire-harness routing.

2010 FI Diagnosis and Required Test Equipment

The FI material goes well beyond a system overview. It provides sensor-data displays, actuator checks, stored-fault history, Power Tuner setting-history and erasure functions, and fault-isolation tables for crankshaft, throttle, pressure, temperature, lean-angle, ignition, injector, EEPROM, and ECU power-supply faults. These procedures call for FI diagnostic tool YU-03182 / 90890-03182 and sub-lead YU-03212 / 90890-03212, plus an external 12-volt battery because the motorcycle has no onboard battery. The optional YZ Power Tuner 33D-859C0-10 is identified as well.

Country-specific tool listings provide both U.S./Canada and 90890-series numbers for the fuel-pressure gauge and adapter, crankshaft installer, crankcase separator, valve-guide tools, fork cap and ring wrenches, fork-seal driver, electrical tester, and ignition checker.

Diagrams, Specifications, and Track Setup

Visual references include the FI system schematic, engine lubrication diagrams, cable and hose routing diagrams, electrical component-location view, full wiring diagram, and sensor-operation and fault-code charts. Major repair sections open with exploded assembly views and numbered job charts. The tuning chapter adds optional sprocket and suspension-spring part numbers, fork oil and air-spring setup, rear spring preload, compression/rebound adjustment, and symptom-based front and rear suspension charts.

Workshop Cautions and Scope

Camshaft work includes a clear timing trap: turning the crankshaft during cam installation can cause damage or incorrect valve timing, while uneven cam-cap tightening can damage the head, caps, and camshaft. On the throttle body, the stop screw, pulley nut, and throttle-valve screw are not routine adjustments; disturbing them can reduce performance, while compressed-air cleaning can drive contamination into the pressure-sensor and injector passages.

The nitrogen-charged rear shock is treated as a sealed assembly. Removal, bearing service, inspection, spring setup, and damping adjustment are covered, but opening the cylinder or reservoir is expressly prohibited. Fuel-system repair must be performed away from ignition sources, and brake work requires clean specified fluid and complete bleeding before operation.