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

The 2007 Buell Blast P3 factory service manual covers the carbureted 492 cc, single-cylinder, air-cooled four-stroke. It 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. The factory schedule also marks certain jobs for an authorized dealer unless the mechanic has the proper tools, service data, and qualifications.

• Document identity: Factory publication P/N 99492-07Y, supplied as 24 PDF files. The set contains 428 unique manual pages; the files total 440 pages because one 12-page Appendix B wiring segment is duplicated.

• Engine repair: Covers compression and cylinder-leakage diagnosis, engine removal and installation, cylinder-head disassembly, valves and valve seats, rocker arms and pushrods, the cylinder and piston, hydraulic lifters, the gerotor oil pump, cam gears, crankcase, flywheel, and shaft bearings.

• Drive and transmission work: Details primary-chain and clutch-release service, clutch-pack inspection, five-speed constant-mesh transmission removal, case separation, mainshaft and countershaft disassembly, shift-fork and drum work, main-drive-gear and case-bearing replacement, reassembly, and shifter-pawl adjustment.

• Chassis and brake repair: Includes wheel removal, sealed-bearing replacement, cast-rim runout checks, tire service, front and rear master-cylinder and caliper overhaul, brake bleeding, fork disassembly with bushing and seal replacement, steering-head bearing service, swingarm work, engine isolators, and drive-belt inspection and replacement.

• Fuel, starting, and electrical diagnosis: Covers carburetor top- and bottom-end service, float and passage checks, the wax-element auto-enrichener, throttle-position-sensor calibration, California and 49-state vapor-system routing, starter voltage-drop and current-draw tests, breakerless ignition fault tracing, charging-system tests, and speedometer self-diagnostics.

• Factory reference data: Supplies section-specific torque tables, fluid requirements and capacities, adjustment data, wear limits, electrical test specifications, connector locations, troubleshooting charts, wiring diagrams, and an illustrated special-tool appendix with factory part numbers.

Maintenance and Model Identification

Routine coverage goes well beyond oil changes. The maintenance section addresses brake and wheel inspection, clutch and primary-chain adjustment, drive-belt wear analysis, steering-head checks, ignition timing and idle adjustment, starter-interlock testing, headlamp alignment, and critical-fastener inspection. The VIN table lets the owner confirm the KP Blast, 01 492 cc engine, and 2007 model-year code 7, while also decoding the market-configuration field before repair information is selected.

Repair Scope and Diagnostic Depth

The engine chapter distinguishes top-end work that can begin with the crankcase still in the chassis from pinion- and sprocket-shaft bearing repairs that require engine removal. Compression and leakdown results are tied to rings, valves, and head-gasket faults before teardown. Once the engine is out, the manual carries the job into flywheel end-play setup, crankcase separation, bearing selection, piston-oil-jet service, and final installation. The rear shock is a clear scope limit: its damper component is not serviceable and must be replaced if defective.

Electrical diagnosis is equally specific. No-spark flowcharts isolate power, fuse, handlebar-switch, 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, battery load tests, and speedometer trouble codes with dedicated test charts.

Diagrams, Tools, and Shop Cautions

The manual contains 522 numbered figures and 92 numbered tables. Particularly useful named visuals include Transmission Power Flow, California Evaporative Emissions Control System Schematic, 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.

Several cautions can prevent expensive damage during repair. A removed engine must not be laid on its primary side because the clutch-cable end fitting can be damaged, and driving the carburetor float pin from the wrong pedestal can damage the carburetor badly enough to require replacement. The factory warnings also address lift and stand support, fuel and battery hazards, brake-fluid compatibility, and low-speed brake verification after hydraulic work. Pre-delivery/setup instructions and parts-catalog information belong to separate factory publications and are not part of this service manual.