Buell P3 2004 - Precision Service & Repair Manual (2004)
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Purchase Information
Technical Specifications
- Document Number / Seller:
- 30660 / Barbara Wright
- File Size:
- 14.19 MB
- File Type:
- Language:
- English
- Pages:
- 408
- Printable:
- Yes
- Estimated Download Time:
- 0.29 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Motorcycle
- Brand:
- Buell
- Reviewed and Approved:
- Jan 11, 2026
Buell Models and Parts Covered in this Motorcycle Manual
- Harley-Davidson Buell Blast P3 Series (2004) — Series: 99492–04Y
- Full Coverage: Buell Blast P3 World, Buell Blast P3 California
Buell Clutch — Sems screws with washers (1) tighten to 84–108 in–lbs (9.5–12.2 Nm). Buell Wheel — Rear axle nut (metric) (1) tightens to 48–52 ft–lbs (65.1–70.5 Nm). Buell Fork — Upper triple clamp cap nut (1) tightens to 28–32 ft–lbs (38–43 Nm) after seating. Buell Engine — Cylinder head screws (1) tighten in sequence to final stage of 85°–95° additional turn. Buell Brake — Caliper mounting screws (6) apply LOCTITE 272 and tighten to 18–22 ft–lbs (24–30 Nm). Buell Ignition — Spark plug HD No. 10R12A (6) gap is 0.035 in. (0.9 mm) and tightens to 11–18 ft–lbs (14.9–24.4 Nm).
Complete Manual Information
Harley-Davidson Buell Blast P3 Technical Workshop Manual
Technical Applicability & Serial Ranges
- Harley-Davidson Buell Blast P3 World (2004): 492 cc Single Cylinder Air-Cooled Architecture.
- Harley-Davidson Buell Blast P3 California (2004): Evaporative Emission Control Framework.
- Harley-Davidson Buell Blast P3 Series (99492–04Y): OEM Factory Reference Standard.
- Harley-Davidson Buell Blast P3 (Domestic/INTL): KEIHIN CV 40 mm Carburetion Logic.
- Harley-Davidson Buell Blast P3 (Chassis Group): Showa 37 mm Front Fork Parameters.
Engineered for the 492 cc single-cylinder platform, the Harley-Davidson Buell Blast P3-2004 necessitates a disciplined approach to maintenance to preserve the unique air-cooled performance characteristics and structural integrity of the chassis. Buell motorcycles utilize a specialized isolator mounting framework that separates engine vibration from the frame, requiring precise torque application on all engine-to-mount interfaces to prevent frequency interference. Proper alignment is critical for safety.
Mechanical synchronization of the valve train involves a zero-maintenance hydraulic lifter design, yet the primary drive chain requires manual adjustment via the inspection cover to maintain the 0.375–0.500 inch slack specification. Precise tensioning prevents gearbox wear. Professional maintenance of the Showa front fork assembly involves a specific oil volume of 10.3 oz (305 cc) per leg to ensure the damping curves remain within factory-defined damping parameters. Consistency ensures stability.
Engineering Intelligence & Logic
Operating the Harley-Davidson Buell Blast P3-2004 requires specialized hardware to ensure that the unique swingarm-mounted engine configuration remains perfectly calibrated during high-stress maneuvers. Utilizing the B-41177 Front Fork Holding Tool is mandatory when performing internal damping rod service, as this specialized bracket prevents the inner tube from rotating during the application of high-torque loads on the bottom bolt. This tool-assisted process ensures that the internal compression valves seat correctly without compromising the specialized coating on the stanchions.
| Buell Blast P3 Calibration Matrix | Parameter / Tool Value |
|---|---|
| Rear Axle Nut Torque | 48–52 ft–lbs (65.1–70.5 Nm) |
| Cylinder Head Final Phase | 85°–95° Additional Turn |
| Spark Plug Gap (HD No. 10R12A) | 0.035 in. (0.9 mm) |
| Tire Pressure (Front/Rear) | 28 psi / 30 psi |
| Sems Clutch Screw Load | 84–108 in–lbs (9.5–12.2 Nm) |
Calibrating the TP Sensor/Auto-Enrichener interface involves a specific electrical diagnostic routine to verify that the throttle plate angle correlates correctly with the voltage signals sent to the ignition logic. Because the carburetor uses a vacuum-operated slide, any leak in the manifold boot will lead to a lean condition that can cause rapid overheating of the cylinder head fins. Precise vacuum sealing is paramount for engine longevity.
FAQ
Diagnostic tool and pressure point logic for Harley-Davidson Buell Blast P3? B-41177 Front Fork Holding Tool ensures secure damper rod removal while maintaining strict alignment of the internal valving logic. For drivetrain verification, technicians utilize the B-43982 Sprocket Locking Tool to immobilize the primary drive during high-torque operations, permitting precise maintenance of the compensator nut and clutch assembly without risking damage to the internal gear architectures.
Relationship between 99492–04Y and other Buell service volumes? Harley-Davidson specifies that this 2004 Buell P3 Service Manual serves as the primary technical framework, often utilized alongside official Parts Catalogs and Electrical Diagnostic Manuals for exhaustive troubleshooting of the 492 cc single-cylinder engine and specialized chassis parameters.
Workshop compatibility for Harley-Davidson Buell Blast P3 print-outs? High-resolution 1200 dpi output ensures that internal wiring logic schematics and exploded views remain legible during physical workshop operations.
Verification of Buell Blast P3 logic-framework schematic depth? Connector [88] for the TP Sensor/Auto-Enrichener provides specific voltage feedback for ignition logic calibration via tamper-resistant T20 TORX screws.
Engine and drivetrain repair coverage for Harley-Davidson Buell Blast P3? Cylinder head screws require a specific sequence culminating in a final 85°–95° additional turn for proper gasket compression.
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Frequently Asked Questions - Buell Motorcycle Manual
Is this manual suitable for beginners?
Yes, this Buell manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Motorcycle maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (14.19 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Buell Motorcycle manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Are engine specifications included?
This motorcycle service manual includes detailed engine specifications, valve clearances, torque settings, and performance data specific to your Buell model.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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