Buell P3 Blast Service Manual (2007)

Buell introduced the Blast for the 2000 model year as a purpose-built entry point into motorcycling rather than a smaller version of one of its sport models. The project was closely associated with Harley-Davidson’s Rider’s Edge training program and was designed around low-speed confidence, approachable ergonomics, low ownership cost and mechanical simplicity. Contemporary Cycle World testing described the Blast as a machine intended to help create new riders while still being 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 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.

By 2007 the Blast was a mature, established design rather than a newly revised generation. Factory specifications for that year list a 1,397 mm wheelbase, 25-degree rake, 86 mm trail, 648 mm low-seat height, 699 mm high-seat height and 177 kg wet weight. Fuel capacity remained 10.6 litres and the motorcycle continued on 16-inch Dunlop K330 tyres. These proportions, together with predictable power delivery and a narrow chassis, preserved the model’s role as an entry-level 492 cc single-cylinder motorcycle for training, commuting and everyday road use rather than outright performance.

The Blast remained mechanically distinct from Buell’s increasingly radical XB sport and streetfighter range. While the XB machines adopted fuel-in-frame aluminum chassis, perimeter brakes and larger V-twins, the Blast continued with its conventional steel chassis, carbureted single and belt-drive layout. Harley-Davidson’s official 2007 parts catalog identifies model code KP as Blast, engine type 01 as 492 cc and model-year code 7 as 2007. The same platform remained in production through 2009, when Harley-Davidson announced the end of Buell motorcycle production. See Harley-Davidson’s official 2007 Blast parts catalog.

This factory publication covers the 2007 Blast and is identified as part 99492-07Y. Its title page and VIN section both identify the 2007 model year, matching Harley-Davidson’s official service-publication index. Related documentation is grouped in the Buell Blast service manual catalog.