Buell P3 Blast Service Manual (2006)

Buell introduced the Blast for the 2000 model year as a purpose-built entry point into motorcycling rather than a reduced version of one of its larger sport models. The project was tied closely to Harley-Davidson’s Rider’s Edge training program and emphasized low-speed confidence, approachable ergonomics, low ownership cost and mechanical simplicity. Contemporary Cycle World testing described the Blast as a motorcycle designed specifically to attract new riders while remaining capable enough for normal road use. See Cycle World’s original Buell Blast road test.

The P3 platform centered on a 492 cm³ air-cooled four-stroke single with an 88.8 mm bore, 79.375 mm stroke and 9.2:1 compression ratio. Pushrod valvegear, hydraulic self-adjusting lifters, a 40 mm Keihin constant-velocity carburetor, five-speed gearbox and belt final drive kept the motorcycle straightforward to operate and maintain. Cycle World’s engineering feature on the model explained that the engine shared manufacturing heritage with Harley-Davidson’s V-twins but was substantially redesigned around the lower cost, lower mass and operating requirements of a single-cylinder motorcycle.

Chassis design followed the same accessibility-first brief. For 2006 the Blast retained 16-inch wheels, a 1,404 mm wheelbase, 25-degree rake and 86 mm trail, with factory low- and high-seat heights of 648 mm and 698 mm. Wet weight was listed at 172 kg and fuel capacity at 10.6 litres. These dimensions, together with modest power delivery and a narrow chassis, preserved the Blast’s role as an entry-level 492 cc single-cylinder motorcycle for rider training, commuting and everyday road use rather than performance riding.

The 2006 model sat in the mature middle-to-late period of the Blast’s single-generation run. Its core engine, carbureted induction, belt drive, chassis proportions and seat-height options remained consistent with the original concept even as Buell’s performance range had moved to the much more radical XB architecture. Harley-Davidson’s official 2006 parts catalog still identifies model code KP as Blast and model-year code 6 as 2006, while documenting the revised VIN format used on motorcycles built after mid-2005. See Harley-Davidson’s official 2006 Blast parts catalog. The Blast continued into Buell’s final years before Harley-Davidson ended Buell motorcycle production in 2009.

This factory publication covers the 2006 Blast P3 and is identified as part 99492-06Y. Its title page and VIN sections both identify the 2006 model year, matching Harley-Davidson’s official service-publication index. Related documentation is grouped in the Buell P3 Blast service manual catalog.