2006 Buell P3 Service Manual (P/N 99492-06Y)

This 2006 Buell service manual covers the Buell Blast P3 (model code KP) and provides factory repair information well beyond routine owner maintenance. Its teardown, measurement, and electrical test content is suited to mechanically qualified owners and technicians with the proper shop tools; the manual directs specified service items to an authorized Harley-Davidson dealer unless the user has the required tools, service data, and qualifications.

• Buell Part Number 99492-06Y, with an April 15, 2005 print line and 419 pages in the PDF. The VIN tables document the coding used before and after the June 2005 production change and identify the 492cc world engine, market or calibration coding, and East Troy assembly plant.
• Engine repair coverage includes motorcycle stripping, engine removal and installation, cylinder-head overhaul, valve-guide and seat work, piston and cylinder service, oil-pump repair, cam-gear selection, and crankcase bearing work.
• Chassis procedures address front and rear brake master cylinders and calipers, brake bleeding, sealed wheel bearings, cast-rim runout, full front-fork service, steering-head bearings, the swingarm, drive belt, and front and rear isolators.
• The primary-drive and five-speed transmission chapters document clutch-pack inspection, clutch hub and shell service, transmission removal, mainshaft and countershaft disassembly, shifter-fork and drum work, main-drive-gear service, bearing replacement, and shifter-pawl adjustment.
• Fuel and starting sections cover carburetor removal and internal service, throttle-position sensor adjustment, auto-enrichener diagnosis, California evaporative-emissions hardware, starter circuit fault isolation, current-draw tests, and starter disassembly and inspection.
• Electrical diagnosis extends to the integrated ignition module and cam-position sensor, bank-angle sensor, starter/ignition interlock, charging system, alternator, regulator, electronic speedometer, indicators, switches, and main wiring harness.

Engine, Chassis, and Drivetrain Repair

The maintenance section supplies service intervals, approved-fluid requirements, a quick-reference maintenance chart, critical-fastener torque data, and system troubleshooting. It covers brake and tire inspection, primary-chain and clutch adjustment, transmission fluid service, drive-belt checks, ignition timing, idle-speed adjustment, and electrical-switch testing.

Engine coverage reaches full teardown and internal repair. The manual explains compression and leakdown diagnosis, rocker-arm and valve inspection, valve-guide replacement, valve-seat cutting, piston and cylinder fitting, oil-reservoir and hose routing, gerotor oil-pump service, hydraulic lifters, cam and pinion gear matching, and crankcase bearing selection and race lapping. Tables provide new-component dimensions, service wear limits, fits and clearances, torque specifications, lubricant data, and inspection criteria for the covered assemblies.

Both hydraulic brake systems receive repair-level coverage, including master-cylinder and caliper disassembly, cleaning, inspection, reassembly, bleeding, and a dedicated brake troubleshooting table. Front-fork coverage includes complete teardown, bushing and seal replacement, spring inspection, oil refill, and installation. The rear-shock damper is identified as non-serviceable; its chapter covers inspection, removal, and assembly replacement, not internal shock overhaul.

Fuel, Starting, and Electrical Diagnosis

Fuel-system material distinguishes California evaporative-emissions plumbing from the 49-state configuration. It documents the fuel tank, supply and rollover valves, carburetor top and bottom ends, auto-enrichener, and throttle-position sensor. Starter coverage includes relay and solenoid checks, activation-circuit diagnosis, voltage-drop and current-draw testing, armature and commutator inspection, growler testing, and motor reassembly; the solenoid is tested as an assembly and is not disassembled.

Electrical connector tables identify numbered connectors, component assignments, and locations, followed by terminal-service instructions for Deutsch and Amp Multilock connectors. Diagnostic flowcharts support no-spark, drivability, interlock, charging, and speedometer repair. Six dedicated 2006 Blast P3 schematics cover the Main Harness, Starting, Charging, Horn and Instruments, Lighting, and Ignition circuits.

Factory Tools, Scope Limits, and Repair Cautions

The 14-page illustrated tool appendix identifies factory tools by part number, including the B-43987 engine cradle, B-43985 transmission remover/installer, B-43991 fork seal/bushing driver, and HD-38361 cam-gear gauge-pin set. Electrical procedures also call out the HD-41354 speedometer tester and the HD-42682 breakout box where applicable.

The manual warns that loosening or tightening cylinder-head fasteners out of sequence can distort the head, cylinder, and crankcase studs. It also explains that pressing the clutch hub and shell apart requires bearing replacement, so that assembly is not separated for routine clutch-pack repair. Fuel-system, brake, battery, and lifted-motorcycle work should follow the fire, fluid-handling, electrical, and support precautions stated in the manual.