Buell Blast P3 Service Manual, 2001 (P/N 99491-01Y)

The 2001 Buell P3 Service Manual (P/N 99491-01Y) covers the Blast P3 across maintenance, chassis, engine, fuel system, electric starter, drive/transmission, and electrical systems, with California-specific emissions information.

Searchable Text, Bookmarks and Wiring Detail

Chapter access and diagram detail: Searchable PDF text and embedded bookmarks provide access to the service chapters and appendices. Small connector numbers, pin labels, and wire-color codes on the inspected main-harness and ignition diagrams are readable when enlarged.

One printable English PDF contains 394 pages total, including the title and contents pages, 28 appendix pages, and the file’s blank and notes pages.

Engine Overhaul, Chassis Service and Fault Diagnosis

This content preview highlights selected procedures rather than the full table of contents. Additional topics include molded-in-color body-panel care and wheel balancing.

• Engine repair: Step-by-step procedures for engine removal and installation, cylinder-head and valve-guide/seat work, cylinder and piston service, and crankcase repair.

• Chassis and brakes: Front and rear wheel service, sealed-wheel-bearing replacement, front-fork overhaul, steering-head work, and master-cylinder and caliper rebuilding and bleeding.

• Fuel and emissions: Carburetor disassembly and inspection, auto-enrichener service, throttle-position-sensor replacement, and California EVAP component and hose-routing information.

• Clutch and transmission: Primary-drive and clutch-pack repair, transmission disassembly and assembly, main-drive-gear and case-bearing service, and shifter-pawl adjustment.

• Electric starter: Starting-system diagnostic charts, on-motorcycle current-draw testing, starter bench tests, solenoid checks, and internal starter inspection and assembly.

• Electrical diagnosis: No-spark and drivability charts, ignition timing, throttle-position-sensor calibration, starter/ignition interlock tests, charging-system diagnosis, and electronic speedometer fault finding.

• Wiring and connectors: Six electrical sheets cover the main harness, starting, charging, horn/instruments, lighting, and ignition, supported by Deutsch and AMP Multilock connector-service instructions.

Suited to technicians familiar with engine measurement and electrical testing, with workshop lifting equipment and the specified specialty tools available for major repairs.

Engine Inspection and Lubrication

Valve operation uses hydraulic self-adjusting lifters rather than periodic valve-lash adjustment. The engine section gives valve-to-guide fits, spring specifications, piston/cylinder limits, rocker-arm clearances, lifter limits, oil-pump limits, cam-gear selection data, and crankshaft/flywheel measurements.

Compression and cylinder-leakage test tables relate test results and air-leak locations to possible valve, piston-ring, cylinder, or head-gasket problems. This supports fault isolation before deciding how far the engine needs to be dismantled.

The engine-removal sections warn that resting the engine on its primary side can damage the clutch-cable end fitting, while repeated front-isolator-mount removal can damage cylinder-head threads.

Primary Drive and Internal Transmission Work

Internal transmission service requires engine removal and splitting the crankcase halves. The procedures extend to the mainshaft and countershaft assemblies, shifter forks and drum, main drive gear, and left and right transmission-case bearings.

The primary-drive chapter warns that incorrect orientation of the mainshaft washer marked “out” can damage the transmission.

Chassis Service and Maintenance Data

Swingarm and front/rear isolator procedures accompany the wheel, brake, fork, and steering sections. The rear shock absorber is treated as a replacement assembly rather than a rebuild item.

Maintenance tables cover initial and recurring oil/filter services, primary-chain adjustment, brake-fluid replacement, and front-fork oil changes. Supporting data includes transmission/primary and fork capacities, wheel-bearing end-play limits, brake-rotor thickness limits, and drive-belt deflection criteria. Drive-belt tension is not adjustable.

California EVAP and Fuel-System Differences

California machines use a rollover valve, charcoal canister, purge plumbing, and dedicated hose routing. The 49-state configuration omits the charcoal canister and vents differently. The EVAP schematic and routing views distinguish the connections before hoses or components are serviced.

Carburetor troubleshooting addresses overflow, poor idle, hard starting, poor acceleration, fuel economy, and vacuum-piston faults.

Starter, Ignition and Charging Tests

Connector IDs and test points tie the diagnostic charts to the wiring documentation, helping trace starting and charging faults through the relevant circuits. Starter coverage includes free-running current, solenoid pull-in and hold-in tests, and brush and armature inspection.

Electrical reference data includes alternator output, regulator voltage, and ignition-coil resistance specifications. All 2001 Blast P3 models have a bank-angle sensor; the manual describes ignition shutoff beyond a 55-degree lean angle.

The starter relay and integrated ignition module are replacement items rather than rebuild assemblies.

Assembly Views and Specialty Tools

Named illustrations include Gearcase Cover & Cam Assembly, Carburetor Assembly, Starter Assembly, and Transmission Power Flow. Appendix B adds the 2001 Buell Blast P3 Model – Main Harness and 2001 Buell Blast P3 Model – Charging sheets.

Appendix A identifies equipment including the B-43985 Transmission Remover/Installer, B-43933 Wheel Bearing Remover/Installer, HD-38515-A Clutch Spring Compressing Tool, HD-35667A Cylinder Leakdown Tester, and HD-39965 Deutsch Terminal Crimp Tool.

Setup Scope and Workshop Precautions

Pre-delivery operations are assigned to the separate model-year Predelivery and Setup Manual; this service manual does not replace that publication.

Motorcycle repair on the P3 involves gasoline and EVAP vapors, DOT 4 hydraulic brakes, high-current starter circuits, and lifting/supporting the engine and chassis. Follow the safety warnings, electrical isolation requirements, and torque specifications in the manual before carrying out repair work.

A Preview of Compression and TP Sensor Test Data

Cylinder testing: The compression-test section specifies normal operating temperature when possible and wide-open throttle, with final readings of 120 psi or more considered normal. Its warm-engine cylinder-leakage test identifies 12% leakdown or more as requiring further attention.

TP sensor calibration: The specified output is 0.50 ± 0.02 V with the throttle fully closed, rising smoothly to no more than 3.7 V at wide-open throttle. The procedure uses the HD-42962 harness adaptor and a breakout box.