- Document Number / Seller:
-
27011 / Ronald Rodriguez
- File Size:
- 66.13 MB
- File Type:
- ZIP
- Language:
- English
- Pages:
- * Covers the **2008 Buell P3 Blast** with VIN identification and dedicated California evaporative-emissions information; Buell factory publication **P/N 99492-08Y**, copyright 2007.
, * Details **engine and crankcase repair**, including motorcycle stripping for engine service, engine installation, cylinder-head and valve work, cylinder/piston service, oil pump and hydraulic lifters, cam gears, and crankcase disassembly and assembly.
, * Covers **chassis and brake service**, including wheels and sealed bearings, tire removal and installation, brake master-cylinder and caliper overhaul, brake bleeding, front-fork rebuilding, steering-head service, swingarm, shock, and engine isolators.
, * Includes **clutch and five-speed transmission repair**, with transmission case removal, gearshaft and shift-drum disassembly, bearing replacement, transmission reassembly, shifter-pawl adjustment, and sprocket service.
, * Provides **fuel and electrical diagnosis**, including carburetor and auto-enrichener repair, starter and charging-system testing, TPS calibration, ignition and interlock diagnostics, connector repair, speedometer testing, and Blast P3 wiring diagrams.
,
, ## Publication and Model Coverage
,
, The 452-page PDF includes seven service chapters plus connector and wiring appendices, conversion data, reference material, and an index. Its foreword identifies the major repair methods as field-tested and factory-approved.
,
, The VIN section identifies the Blast as motorcycle type **KP**, engine type **01** for the 492 cc single-cylinder engine, model-year code **8**, and model code **0**. It also decodes domestic, California, Canadian, European, and other export market configurations. California models receive a dedicated EVAP chapter with charcoal-canister components and hose routing, while the same section explains the different vent routing used on non-California machines. The quick-reference maintenance chart carries separate lines for solo riding and rider-with-passenger use, and the seat chapter documents the two available seat thicknesses.
,
, ## Scheduled Maintenance and Chassis Repair
,
, The maintenance chapter supplies the **Regular Service Intervals** table and **Quick Reference Maintenance Chart** for engine oil and filter, transmission lubricant, primary-chain adjustment, clutch, drive belt and rear sprocket, brake fluid and pads, tires, steering-head bearings, fork oil, shock, engine mounts, electrical equipment, and road-test checks. Fluid requirements, inspection limits, critical-fastener data, and troubleshooting are tied directly to the relevant procedures rather than presented as generic motorcycle specifications.
,
, Chassis coverage extends into removal, disassembly, inspection, assembly, and installation. It includes front and rear wheels, sealed wheel bearings, cast-rim runout, tire service and balancing, front and rear brake master cylinders, calipers and lines, brake bleeding, front-fork overhaul, fork-stem and steering-head service, swingarm, rear shock, sidestand, handlebars, tail section, exhaust, and the front and rear engine isolators.
,
, ## Engine, Fuel, Clutch, and Transmission Work
,
, Engine diagnosis begins with compression and cylinder-leakage testing. The manual then covers stripping the motorcycle for engine and top-end access, lifting the chassis away from the engine, and reinstalling the assembly. Internal repair sections address cylinder-head removal and disassembly, rocker arms, valves, guides and seats, Neway valve-seat cutting, pushrod covers, cylinder and piston inspection, ring fitting, oil-pressure testing, crankcase breathing, the gerotor oil pump, oil-filter mount, hydraulic lifters, gearcase cover and cam gears, piston jet, flywheels, crankcase main-bearing race lapping, and final crankcase assembly.
,
, Fuel-system sections cover the tank and cover, cap, supply valve, rollover valve, air cleaner, carburetor removal, separate top- and bottom-end carburetor disassembly, air/fuel-passage cleaning, float adjustment, reassembly, auto-enrichener service, and the California emissions hardware.
,
, The drive/transmission chapter documents internal repair, not only routine adjustment. It covers primary-chain removal and installation, clutch-release service, wet multi-disc clutch disassembly and inspection, transmission case removal, full five-speed transmission teardown, mainshaft and countershaft subassemblies, shift forks and drum, main-drive gear, case bearings, transmission installation, shifter-pawl adjustment, and transmission-sprocket repair.
,
, ## Electrical Diagnosis, Diagrams, and Special Tools
,
, Electrical coverage includes starter-circuit operation, voltage-drop tests, on-motorcycle starter testing, testing the starter as an assembled unit, armature and field-coil checks, starter repair, and solenoid replacement. Ignition and chassis-electrical sections add diagnostic flowcharts, throttle-position-sensor calibration and testing, bank-angle sensor service, auto-enrichener diagnostics, ignition-module/cam-position-sensor timing, coil and plug-cable tests, starter-interlock diagnosis, charging-system output and stator tests, alternator service, speedometer diagnostic mode and performance checks, indicator-lamp diagnosis, and main-harness removal and installation.
,
, Appendix A covers AMP Multilock and Deutsch connector repair plus sealed-splice work. Appendix B identifies connector numbers and locations, then supplies six P3 wiring sheets for the **main harness, starting, charging, horn and instruments, lighting, and ignition**. Named illustrations include the **Crankcase Breather System**, **California Evaporative Emissions Control System**, **Starter Components**, and **Transmission Power Flow**.
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, The reference section indexes required tools by part number, including the **B-43985-series transmission remover/installer fixtures**, **HD-35758-C Neway valve-seat cutter set**, **HD-42682 breakout box with HD-42962 adaptors**, and **HD-41354 speedometer tester**. It also provides a consolidated torque reference, component specifications, capacities, wear limits, clearances, electrical test values, troubleshooting tables, and conversion data.
,
, ## Repair Notes and Safety Scope
,
, Several Blast-specific repair traps are called out. Repeated removal of the cylinder-head isolator mount can damage the head threads, and placing the engine on its primary side can damage the clutch-cable end fitting. The primary-drive washer marked “out” has a required orientation to prevent transmission damage; the wheel procedures also warn that operating a brake control with the wheel removed can force the caliper piston out.
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, Before fuel, brake, engine, fork, or drivetrain repair, follow the manual’s procedures for supporting the motorcycle, isolating the battery, controlling fuel and brake-fluid exposure, and handling spring-loaded or suspended assemblies.
- Printable:
- Yes
- Category:
- Motorcycle
- Last updated / verified
- Aug 27, 2026
