Buell Blast P3 2007 Service Manual (P/N 99492-07Y)

The 2007 Buell Blast P3 factory service manual, P/N 99492-07Y, covers maintenance, diagnosis, and repair of the carbureted model.

Searchable PDFs and Wiring Diagram Detail

Text search, bookmarks, and circuit labels: The PDFs contain searchable text. Embedded bookmarks navigate the main service files and appendices; the separate chapter contents files and duplicated wiring file have no bookmarks. Small wiring labels require zooming, and several circuit sheets have faint gray lines.

The ZIP contains 24 printable English PDF files totaling 440 pages: 428 pages plus a duplicated 12-page Appendix B segment. Contents, blank and notes pages, diagram-title-only pages, and one page with stray text are included in these totals.

Engine Overhaul, Drivetrain Service, and Electrical Fault Tracing

The following topics are selected highlights, not a complete contents list. Other covered work includes exhaust-system removal and installation and throttle-control servicing.

• Engine repair: Compression and leakdown diagnosis, engine removal and installation, cylinder-head overhaul, cylinder and piston service, hydraulic lifters, cam gears, and crankcase repair.

• Drive and transmission: Primary-chain and clutch-release service, clutch-pack inspection, transmission teardown and assembly, mainshaft and countershaft work, shift forks and drum, bearing replacement, and shifter-pawl adjustment.

• Chassis and brakes: Wheel and tire service, sealed-bearing replacement, cast-rim runout checks, master-cylinder and caliper overhaul, brake bleeding, fork rebuilding, steering-head bearings, swingarm, engine isolators, and drive-belt replacement.

• Fuel and emissions: Carburetor top- and bottom-end service, float and passage checks, wax-element auto-enrichener diagnosis, throttle-position-sensor calibration, and California and 49-state vapor-system routing.

• Starting and electrical diagnosis: Starter voltage-drop and current-draw tests, breakerless ignition fault tracing, charging-system tests, battery load testing, and speedometer self-diagnostics.

• Factory reference data: Section-specific torque tables, fluid requirements and capacities, adjustment data, wear limits, electrical test specifications, connector locations, wiring diagrams, troubleshooting charts, and illustrated special-tool references.

This manual is suited to professional technicians and mechanically experienced owners with a properly equipped shop, since the procedures rely on motorcycle support equipment, precision measuring tools, electrical test gear, and model-specific service tools.

Maintenance and Engine Repair Depth

The maintenance schedule and quick-reference charts cover routine servicing and inspection. Ignition timing and idle adjustment, starter-interlock testing, headlamp alignment, and critical-fastener checks are documented alongside brake, wheel, clutch, primary-chain, drive-belt, and steering-head maintenance.

The factory schedule marks certain jobs for an authorized dealer unless the mechanic has the proper tools, service data, and qualifications.

Diagnosis before teardown: Compression and cylinder-leakage results are linked to ring, valve, and head-gasket faults. These references help assess whether a running problem calls for further testing or internal engine inspection.

The engine chapter distinguishes top-end work with the crankcase remaining in the chassis from pinion- and sprocket-shaft bearing repairs that require engine removal. Step-by-step procedures cover cylinder-head disassembly and assembly, valve-guide replacement, Neway valve-seat cutting, rocker-arm bushing replacement, and pushrod installation.

Cylinder work extends to bore measurement, boring and honing, piston-ring fitting, and connecting-rod bushing service. Lower-end coverage includes flywheel end-play setup, crankcase separation, bearing selection, main-bearing race lapping, piston-oil-jet service, and final installation. The gerotor oil-pump section includes removal, inspection, reassembly, and installation.

Transmission Access and Suspension Limits

Internal transmission work: Servicing the transmission components requires engine removal and crankcase separation. The instructions extend through main-drive-gear service and right transmission-case and left crankcase bearing replacement.

Front-fork procedures include disassembly, inspection, and bushing and seal replacement. The rear shock has a different service limit: its damper component is not repairable and requires replacement if defective.

Fuel Controls and Electrical Diagnosis

No-spark flowcharts isolate power-supply, fuse, handlebar-switch, ignition-coil, ignition-module, cam-sensor, and bank-angle-sensor faults. Separate procedures cover starter-relay and solenoid tests, armature and field checks, regulator and stator testing, and speedometer trouble codes with dedicated test charts.

The fuel sections explain the auto-enrichener’s cold-start operation and distinguish California evaporative-emissions plumbing from non-California routing. The auto-enrichener and throttle-position sensor are nonrepairable replacement units, with testing and replacement procedures provided.

Diagrams, Special Tools, and Repair Cautions

The manual contains 538 numbered figures and 95 numbered tables. Transmission Power Flow illustrates gear operation, while the California Evaporative Emissions Control System Schematic documents vapor routing.

Electrical references include Ignition System Circuit, Charging System Troubleshooting, the Speedometer Test Charts, and the 2007 Buell Blast P3 Main Harness. Appendix B adds connector identification and cavity data, plus AMP Multilock, Deutsch-terminal, crimp, and sealed-splice repair procedures.

The 15-page tool appendix identifies equipment by part number, including the B-43985 transmission remover/installer, B-43991 fork seal/bushing driver, HD-35667A cylinder leakdown tester, and HD-39301-A/HD-39302 steering-head bearing tools. Dimensioned Pinion Shaft Bearing Tools drawings support fabrication of press tools for bearing-race work.

Component damage cautions: The engine sections identify clutch-cable end-fitting damage caused by incorrect support of a removed engine. Carburetor instructions flag float-pin handling errors that can damage the body enough to require replacement.

Factory warnings address lift and stand support, fuel and battery hazards, brake-fluid compatibility, and low-speed brake verification after hydraulic work. Predelivery/setup instructions and parts-catalog information belong to separate factory publications.

A Preview of Sensor and Stator Test Specifications

Throttle-position-sensor calibration specifies 0.5 ± 0.05 V with the throttle plate fully closed.

For the stator disconnected from the regulator, the charging-system section specifies 0.2–0.4 ohms across the stator sockets. Its AC-output check gives 38–52 VAC at 2,000 rpm.