Safe Operating Maintenance

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Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a)

Good maintenance creates a safe motorcycle. A careful check of certain equipment must be made after periods of storage. Also, frequently inspect the motorcycle between the regular service intervals to determine if additional maintenance is necessary.

Check the following items:

1. Tires for correct pressure, abrasions or cuts.

2. Belt and primary chain for proper tension, wear or damage.

3. Brakes, steering and throttle for responsiveness and freedom from binding.

4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and discs for wear.

5. Cables for fraying or crimping and free operation.

6. Engine oil and primary chaincase/transmission fluid levels.

7. Headlamp, tail lamp, brake lamp and turn signals for proper operation.

Break-in Maintenance: Buell Models

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After a new motorcycle has been ridden its first 1000 miles (1600 kilometers), take it to an authorized Buell dealer to have an initial service performed.

If it is impossible to take it to a dealer at the mileage intervals noted, the owner should:

1. Give the following outlined items attention or arrange to have the motorcycle serviced.

2. Take the motorcycle to a dealer for more complete servicing as soon as possible.

We recommend a Buell dealer perform the initial service.

When supporting motorcycle, do not place supports under rear brake pedal. Damage to the brake system can occur, which could result in death or serious injury. (00100a)

Initial Service Check: Blast Models

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First 1000 Miles (1600 Kilometers)

The first scheduled maintenance is at 1000 miles (1600 kilometers). See Regular Service Intervals: Buell Models for complete list of required services.

1. Change the engine oil (includes draining the crankcase breather hose).

2. Replace the oil filter.

3. Change primary transmission chain case lubricant and clean drain plug. See dealer.

4. Check clutch adjustment. See dealer.

5. Inspect brake pad linings and discs for wear.

6. Check brake fluid reservoir level and condition. See dealer.

7. Inspect oil lines and brake system for leaks.

8. Check operation of throttle and enrichener controls.

9. Check engine idle speed.

10. Check battery and clean connections.

11. Check operation of all electrical equipment and switches including starter interlock.

12. Check tire pressure and inspect tread.

13. Inspect fuel valve, lines and fittings for leaks.

14. Check/adjust primary chain.

15. Road test.

Lubrication Summary: 2006 Blast Models

Lubrication Points: Blast Models

Service Intervals and Performance: Buell Models

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Regular lubrication and maintenance will help keep your new Buell operating at peak performance. Your Buell dealer knows best how to service your motorcycle with factory approved methods and equipment assuring you of thorough and competent workmanship.

See Regular Service Intervals: Buell Models for more information.

Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a)

If you operate your motorcycle under adverse conditions (severe cold, extreme heat, very dusty environment, very bad roads, through standing water, etc.), you should perform the regular maintenance intervals more frequently to ensure the safe operation of your motorcycle. Failure to maintain your motorcycle could result in death or serious injury. (00094a)

If motorcycle is used frequently for short trips, less than 15 miles (24 kilometers), in ambient temperatures below 60° F (16° C), oil change intervals should be reduced to 1500 miles (2400 kilometers).

Engine Lubrication

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Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life of the engine. Always use the proper grade of oil for the lowest temperature expected before the next scheduled oil change. Refer to Recommended Engine Oils. Your authorized dealer has the proper oil to suit your requirements.

If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include: CF-4, CG-4, CH-4 and CI-4.

The preferred viscosities for the diesel engine oils in descending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change back to 100 percent Harley-Davidson oil.

Recommended Engine Oils

Checking Oil Level: Blast Models

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Engine oil level should be checked only when engine is at normal operating temperature. The engine will require a longer warm up period in colder weather.

The motorcycle should be ridden for approximately 10 minutes to ensure oil is hot and engine is at normal operating temperature.

When the above conditions are met, turn the engine off.

1. The motorcycle should be in the upright position and level (not on sidestand). Place transmission in neutral.

2. See Dipstick Location: Blast Models. Unthread dipstick to remove from frame filler hole.

3. Wipe off dipstick and insert into frame with dipstick threaded completely into filler neck.

4. See Engine Oil Level: Blast Models. Remove dipstick and note oil level.

Do not allow hot oil level to fall below Add/Fill mark on dipstick. Doing so can result in equipment damage and/or equipment malfunction. (00189a)

Do not overfill oil tank. Doing so can result in oil carryover to the air cleaner leading to equipment damage and/or equipment malfunction. (00190a)

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

5. Hot oil level should be between the upper and lower fill marks on dipstick. If oil level is down to or below lower fill mark on dipstick, add only enough oil to bring level between lower and upper "fill" marks.

Change oil after the first 1000 miles (1600 kilometers) for a new engine and at 2500 (4000 kilometers) mile intervals thereafter (at warm or moderate temperatures) when riding in one or more of the following conditions:

• Severe dust conditions.
• Operation during temperatures above 80° F (27° C).
• Extensive idling or speeds in excess of 65 mph (105 kph).
• Extensive two up riding or similar loads.

Shorten the oil change interval in cold weather. See Winter Lubrication.

Dipstick Filler hole Dipstick Location: Blast Models

Correct hot oil level is between arrows Engine Oil Level: Blast Models

Engine Oil Change: Blast Models

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Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

Ride motorcycle for approximately 10 minutes to ensure the oil is hot and the engine is at normal operating temperature. Turn engine off.

1. See Oil Tank Drain Hose: Blast Models. Locate the engine oil tank drain hose (normally the lower hose) and the crankcase breather drain hose (normally the upper hose) inside the foot peg support frame on the left side of the motorcycle.

2. Remove fastener from hose retention clamp.

3. Place a drain pan directly underneath the engine oil drain hose.

4. Loosen the spring clamp and remove engine oil drain drain plug from drain hose.

Hose retention clamp fastener Oil tank drain hose (lower hose) and crankcase breather hose (upper hose) Spring clamp Engine oil drain hose cap Foot peg support frame Oil Tank Drain Hose: Blast Models

Filter mount Tighten oil filter 1/2-3/4 turn after gasket contact Oil Filter Mount: Blast Models

5. Allow used oil to drain completely.

NOTE:


Dispose of used oil in accordance with local regulations.

6. Loosen spring clamp and remove crankcase breather hose drain plug to allow any oil present to drain.

7. See Oil Filter Mount: Blast Models. Remove the oil filter (located at the front of the engine).

8. Clean filter gasket contact surface on mounting plate. Surface should be smooth and free of any debris, used oil or old gasket material.

9. See Prepare Oil Filter. Apply a thin film of clean oil to gasket on new oil filter.

Apply thin film of clean engine oil to gasket Prepare Oil Filter

10. Install new oil filter (Part No. 63806-00Y) onto adapter until gasket contacts plate surface, then tighten another 1/2-3/4 turn. Do not overtighten.

11. Place two drain hoses back on the hose fixture. Install drain plugs to drain hoses and secure plugs with spring clamps.

12. See Dipstick Location: Blast Models. Remove dipstick and refill with approximately 1.5 quarts (1.42 liter) of oil at filler hole. For more information on recommended engine oils, refer to Recommended Engine Oils.

13. Install dipstick and operate motorcycle for 10 minutes to reach normal operating temperature. Check oil level again (hot check) and add oil as necessary until oil registers between marks on dipstick.

Always consider the following when changing your oil.

• Change oil more frequently if bike is operated under severe conditions (dusty, very hot or cold temperatures).
• Drain oil after operating motorcycle (while oil is still very warm).
• The crankcase normally does not accumulate used oil, no draining of the crankcase is required.
• Replace oil filter every time the oil is changed.
• Drain the crankcase breather drain hose of any accumulated oil every time the oil is changed.

Winter Lubrication

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In colder climates, the engine oil change interval should be shorter than normal. Motorcycles used only for short runs must have the engine oil changed more frequently and have a thorough tank flush-out before new oil is put in. See an authorized dealer.

Water vapor is a normal by-product of combustion in any engine. During cold weather operation, some of the water vapor condenses to liquid form on the cool metal surfaces inside the engine. In freezing weather this water will become slush or ice and, if allowed to accumulate too long, may block the oil lines and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm up, most of this water will become vapor again and will be blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly warm up, this water will accumulate, mix with the engine oil and form a sludge that is harmful to the engine.

Transmission Lubrication: Buell Models

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The transmission lubricant level should be checked by a Buell dealer according to specific mileage interval.

The transmission should also be drained and refilled with fresh lubricant at regular intervals.

Refer to Regular Service Intervals: 2006 Blast Models for more details.

Rear Drive Belt: Blast Models

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General

The rear drive belt transfers engine/transmission power to the rear wheel drive sprocket. The rear drive belt is not adjustable.

The rear drive belt inner tooth surface has a thin coating of polyethylene. During initial operation, this coating will wear as it is burnished into the belt fabric. This is a normal condition and not an indication of excessive belt wear.

Adjustment and Replacement

The rear drive belt and sprocket should be replaced every 15,000 miles (24,000 kilometers) by a Buell dealer.

Measure rear belt deflection with a 160 lb. (73 kg) rider or equivalent weight sitting on the motorcycle. The rear wheel must be on the ground.

Top strand 10 lbs (4.5 kg) of force Bottom strand deflection, max 0.5 in (12.7 mm) Measuring Belt Deflection: Blast Models

1. See Measuring Belt Deflection: Blast Models. Using BELT TENSION GAUGE (Part No. HD-35381) apply 10 lbs (4.5 kg) of force at the midpoint of the belt's appropriate strand.

2. Check belt deflection.

   1. The maximum allowable deflection is 0.5 in. (12.7 mm) at the bottom strand.

   2. Replace belt and drive sprocket that exceed maximum allowable deflection. See a Buell dealer.

Be sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury. (00050a)

Chassis Lubrication: Blast Models

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Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

1. Use the recommended bearing grease (Part No. 99855-89) for steering head bearings. Use a multipurpose chassis grease for other applications.

2. Remove and lubricate handlebar throttle control grip sleeve with graphite every 5000 miles (8000 kilometers), once a year or when operation indicates lubrication is necessary.

3. Every 5000 miles (8000 kilometers) lubricate throttle control cables and clutch control cable. Lubricate front brake hand lever and clutch control hand lever only if necessary.

4. Inspect rear swingarm pivot sealed bearings for proper operation. Swingarm should move freely without binding.

5. Pack the steering head bearings with fresh grease at 20,000 (32,000 kilometers) mile interval or every two years, whichever occurs first.

6. Lubricate the sidestand mechanism with lithium grease every 5000 miles (8000 kilometers).

Front Fork Oil: Buell Models

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Incorrect amount of fork oil can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury. (00298a)

Drain front fork oil and refill with TYPE E FORK OIL (Part No. HD-99884-80) at proper mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models.

Incorrect amount of fork oil can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury. (00298a)

If either fork leaks oil or does not seem to be working properly, see a Buell dealer. Forks must contain equal amounts of fork oil for proper damping.

Incorrect recoil action will result if there is insufficient oil in either side of fork. If fork should at any time become submerged in water, drain and refill immediately.

Fuel Strainer

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See Fuel Strainer: Blast Models. A screen type fuel strainer is located on top of the fuel supply valve inside the fuel tank. The screen should be inspected/cleaned at proper mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models.

Check the fuel supply valve, lines and fittings for leakage as part of the pre-ride inspection.

Fuel strainer (in fuel tank) Fuel supply valve Fuel Strainer: Blast Models

Carburetor: Blast Models

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General

The carburetor has been specifically designed for emissions control operation. All jets are fixed at the factory.

Carburetor controls include throttle, auto-enrichener and idle speed adjusting screw. Check all carburetor controls for proper operation at every maintenance interval.

Operation at higher altitudes (approximately 4000 ft. (1200 meters) elevation) can require carburetor modifications for best engine performance. See a Buell dealer for these adjustments. Failure to do so could result in equipment damage. (00238a)

We recommend that any carburetor service be performed by a Buell dealer.

Auto-Enrichener Operation

Your motorcycle is equipped with an auto-enrichener that automatically enrichens the fuel mixture provided to the carburetor at start-up eliminating the need for a manual choke or enrichener. The auto-enrichener increases the idle speed at start-up until the engine is warmed up to the proper operating temperature and then gradually decreases to the correct idle speed. Allow the bike to warm up (idle speed returns to normal) before beginning forward movement.

Clutch: Buell Models

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Clutch control cable adjustment is required to compensate for normal clutch lining wear. Oil and adjust the clutch control cable with LUBIT-8 TUFOIL CHAIN AND CABLE LUBE (Part No. 94968-85TV) at proper mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models.

If the clutch slips under load or drags when released, adjust the clutch control cable. See a Buell dealer or a service manual.

Air Cleaner: Blast Models

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General

The engine air cleaner prevents foreign material from entering the carburetor and engine, trapping airborne dust and dirt in a reusable filter element. Inspect the filter element at proper mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models.

Removal/Installation

1. See Air Cleaner Filter Element: Blast Models. Release five latches that secure airbox cover to airbox. Remove phillips head screw and airbox cover from backplate.

2. Pull conical filter element from airbox.

3. Clean the airbox and cover with a slightly damp cloth.

4. Replace the filter element if damaged.

Do not use gasoline or solvents to clean filter element. Flammable cleaning agents can cause an intake system fire, which could result in death or serious injury. (00101a)

5. To clean filter element, wash in warm, soapy water. To remove soot and carbon, soak element for 30 minutes in warm water and mild detergent. Allow filter to air dry.

NOTE:


Do not use air cleaner filter oil on the filter element.

6. Hold the filter element up to a strong light source. The element can be considered sufficiently clean if lamp is uniformly visible through the filter media.

7. Install filter element into airbox.

8. Note position of index pin on airbox cover and depression on filter element. Position airbox cover onto airbox so that pin engages depression.

9. Push cover onto backplate and install Phillips head screw. Lock five latches around perimeter of airbox cover while pushing on the cover.

Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. (00207a)

Latches (5) Depression Filer element Airbox cover Index pin Air Cleaner Filter Element: Blast Models

Brakes: Blast Models

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General

Inspect brake pads for wear at service maintenance intervals. If you ride under adverse conditions (steep hills, heavy traffic, etc.), inspect more frequently. Excessively worn brake pads can lead to brake failure, which could result in death or serious injury. (00052a)

The brake system needs routine inspections and maintenance at certain intervals. Refer to Regular Service Intervals: 2006 Blast Models for more information.

Brakes are a critical safety component. Contact a Buell dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00117a)

These tasks may include:

• Inspecting front and rear brake pads and brake discs for wear.
• Checking the fluid level in the front and rear master cylinder reservoirs.
• Replacing the rear brake pads and pin.
• Changing the brake fluid and having the brakes serviced. Use only D.O.T. 4 HYDRAULIC BRAKE FLUID.

Always take your motorcycle to a Buell dealer for brake system maintenance.

Brake Pad Inspection

See Brake Pad: Side View. Visual inspection of brake pads can be made without removing the caliper by viewing the lower area of each caliper with the aid of a flashlight.

Metal backing plate Friction material 1/16 in. (1.6 mm) minimum Brake Pad: Side View

Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a)

1. Measure the front brake pad friction material. If the brake pad friction material is 1/16 in. (1.6 mm) thick or less (the thickness of a nickel), the pads must be replaced immediately.

NOTES:

• Always replace brake pads in pairs.
• The rear brake outer pad thickness can be measured from the caliper bracket side using a thin plastic 6 in. rule.

2. See Measuring Rear Brake Outer Pad: Blast Models. Place rule against the brake disc.

3. Measure distance from the outer surface of the brake pad backing plate to brake disc.

   1. The outer surface of the brake pad backing plate should measure 1/4 in. (6.35 mm) or more away from the brake disc.

   2. If it measures less than 1/4 in. (6.35 mm), replace both brake pads immediately. See a Buell dealer.

NOTE:


This 1/4 in. (6.35 mm) dimension includes both the thickness of the backing plate and the minimum 1/16 in. (1.6 mm) of friction material.

Be sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury. (00050a)

Apply front and rear brakes evenly. Favoring one brake accelerates wear and reduces braking efficiency. Operation with excessively worn brakes can lead to brake failure, which could result in death or serious injury. (00135a)

Brake pad Disc Measuring Rear Brake Outer Pad: Blast Models

Tires: Buell Models

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Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. (00027a)

Keep the tires properly inflated. Check tire pressure before riding when tires are cold.

Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Buell dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00114a)

Check inflation pressure and inspect tread for punctures, cuts, breaks, etc. Inspect at least weekly if in daily use or before each trip if used occasionally.

Refer to Tires: 2006 Blast Models for tire pressures and sizes.

Match tires, tubes, air valves and caps to the correct wheel rim. Contact a Buell dealer. Mismatching can result in damage to the tire bead, allow tire slippage on the rim or cause tire failure, which could result in death or serious injury. (00162a)

Use only Buell approved tires. See a Buell dealer. Using non-approved tires can adversely affect stability, which could result in death or serious injury. (00133a)

Replace worn tires with new tires identical to those that came on the motorcycle as original equipment. Other tires may not fit correctly or may be hazardous to use.

Tires are a critical safety component. Contact a Buell dealer for tire repair or replacement. Improper tire service can adversely affect stability and handling, which could result in death or serious injury. (00134a)

Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the demounted tire by a Buell dealer. Speed should NOT exceed 50 mph (80 km/h) for the first 24 hours after repair, and the repaired tire should NEVER be used over 80 mph (130 km/h). Failure to follow this warning could result in death or serious injury. (00118a)

Striking an object, such as a curb, can cause internal tire damage. If an object is struck, remove and inspect both the inside and outside of the tire. A damaged tire can adversely affect stability and handling, which could result in death or serious injury. (00058a)

Tire Replacement: Buell Dunlop Tires

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Inspection

See Tire Sidewall: Blast Models. Arrows on tire sidewalls pinpoint location of wear bar indicators.

Tread wear indicator bars will appear on tire tread surfaces when 1/32 in. (0.8 mm) or less of tire tread remains. See Tread Surface: Blast Models. Always replace tires before the tread wear indicator bars appear.

When To Replace Tires

New tires are needed if any of the following conditions exist:

1. Tread wear indicator bars become visible on the tread surfaces.

2. Tire cords or fabric become visible through cracked sidewalls, snags or deep cuts.

3. A bump, bulge or split in the tire.

4. Puncture, cut or other damage to the tire that cannot be repaired.

Tire Sidewall: Blast Models

Tread Surface: Blast Models

Shock Absorber: Buell Models

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The rear shock absorber requires inspections and maintenance at proper mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models.

• Inspect shock absorber for oil leaks.
• Inspect rubber shock eye bushings for deterioration.
• Check for loose mounting hardware.

See a Buell dealer for all shock absorber repairs.

Vehicle Alignment: Blast Models

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The engine is secured to the frame by front and rear rubber-isolated mounts and by two stabilizer links. Alignment of the front and rear wheel is partially controlled by two of these stabilizer links.

Do not change stabilizer link adjustment. Changing adjustment can adversely affect stability, which could result in death or serious injury. (00059a)

Inspect stabilizer links and front and rear engine mounts and rubber isolators for wear at proper mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models.

Only a Buell dealer should perform vehicle alignment. Improper alignment can adversely affect stability and handling, which could result in death or serious injury. (00136a)

Always see a Buell dealer for any service work involving vehicle alignment.

Wheel Bearings

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The wheel bearings are sealed units. No greasing or maintenance is required.

Inspect wheel bearings each time the wheel is removed. Replace when worn.

Steering Head Bearings: Blast Models

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Adjustments to front fork bearings should be performed by a Buell dealer. Improperly adjusted bearings can adversely affect handling and stability, which could result in death or serious injury. (00137a)

Steering head bearings require inspection and lubrication at proper mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models. Always have a Buell dealer service the steering head bearings.

Spark Plug: Blast Models

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Spark plugs require inspection and replacement at specific mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models.

See a Buell dealer or a service manual for details. Refer to Ignition: 2006 Blast Models for ignition specifications.

Ignition Timing: Blast Models

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Ignition timing should be checked at specific mileage intervals. Refer to Regular Service Intervals: 2006 Blast Models. If ignition timing is not correct, see a Buell dealer.

The engine is designed to achieve optimum fuel economy within exhaust emission controls. Ignition characteristics have been developed to provide maximum engine performance and drivability.

Headlamp: Blast Models

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General

Your motorcycle has a sealed beam type headlamp. The sealed unit is replaced as an assembly. See a Buell dealer or service manual for replacement.

For better visibility wear bright colored clothing and ride with the headlamp on high beam on during daylight hours.

Adjustment

Before performing a headlamp adjustment:

• Inflate tires to proper pressure.
• See Headlamp Adjustment: Blast Models. Have an assistant draw a horizontal line 35 in. (88.9 cm) above the ground on a wall.
• Place motorcycle 25 ft. (7.62 m) away from the wall.
• Configure vehicle with typical cargo, rider and passenger load.

1. With motorcycle upright on level pavement (not on side stand), turn on HIGH beam.

2. At HIGH beam, headlamp should be centered on drawn horizontal line and shine straight ahead of motorcycle.

3. See Headlamp Adjusters: Blast Models. Adjust headlamp as required using a screwdriver.

   1. Turn vertical headlamp adjuster clockwise to raise beam height, counterclockwise to lower beam height.

   2. Turn horizontal headlamp adjuster clockwise to aim beam to the left, counterclockwise to aim beam to the right.

Correct alignment at high beam 35 in. (88.9 cm) 25 ft (7.62 m) Headlamp Adjustment: Blast Models

Vertical headlamp adjuster Horizontal headlamp adjuster Headlamp Adjusters: Blast Models

Voltage Regulator: Buell Models

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The alternator output is controlled and changed to direct current by the voltage regulator.

• The voltage regulator increases charging rate when battery voltage is low or lamps are lit.
• The voltage regulator decreases charging rate when battery charge is up.

It is possible to overload your motorcycle's charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle's charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Buell dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00249b)

Seat: Blast Models

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Removal

Use both hands to operate seat latch. Failure to do so can result in pinched fingers. (00241a)

The seat latch is located under the seat.

1. See Underside of Seat: Blast Models. Using both hands, push or pull the seat latch toward the front of the motorcycle with your thumb.

2. Grasp the rear section of the seat with one hand.

3. Lift seat and remove.

Installation

1. See Underside of Seat: Blast Models. Locate tab on bottom of seat.

2. See Installing Seat: Blast Models. Check that seat is upright. Grasp the rear section of the seat with one hand and grasp the front section of the seat with the other hand.

3. Push seat forward while flexing the rear section of the seat upward until the tongue locks into the bracket located on the frame.

4. Push down firmly on the seat until a click is heard. This click indicates tab and latch have engaged.

NOTE:


You will hear a click when the locating tab and seat latch lock together correctly.

After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

5. Pull upward on rear of seat to make sure seat is locked in position.

Locating tab Seat latch Underside of Seat: Blast Models

Locating Tab: Blast Models

Installing Seat: Blast Models

Battery: General

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Type

Your motorcycle uses a permanently sealed, maintenance-free, lead/calcium and sulfuric acid battery. All batteries are shipped precharged and ready to be put into service. Do not attempt to open the battery for any reason.

Antidotes for Battery Acid

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019d)

Never remove warning label attached to top of battery. Failure to read and understand all precautions contained in warning, could result in death or serious injury. (00064a)

Contents are corrosive Wear safety glasses Contents are explosive Keep flames away Read instructions Keep away from children Battery Warning Label

Battery Warning Label Location

Voltmeter Test

Refer to Voltmeter Test. The voltmeter test provides a general indicator of battery condition. Check the voltage of the battery to verify that it is in a 100 percent fully charged condition. If the open circuit (disconnected) voltage reading is below 12.6V, charge the battery and then re-check the voltage after the battery has set for one to two hours.

Voltmeter Test

Cleaning and Inspection

Battery top must be clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge.

1. Clean battery top with a solution of baking soda (sodium bicarbonate) and water. Use 5 teaspoons baking soda per quart or liter of water.

2. When the solution stops bubbling, rinse off the battery with clean water.

3. Clean cable connectors and battery terminals using a wire brush or fine grit sandpaper to remove any oxidation.

4. Inspect and clean the battery screws, clamps and cables. Check for breakage, loose connections and corrosion.

5. Check the battery posts for melting or damage caused by overtightening.

6. Inspect the battery for discoloration, a raised top or a warped or distorted case. This might indicate that the battery has been frozen, overheated or overcharged.

7. Inspect the battery case for cracks or leaks.

Charging

Never charge a battery without first reviewing the instructions for the charger being used. In addition to the manufacturer's instructions, follow these general safety precautions.

Charge the battery if any of the following conditions exist:

• Vehicle lamps appear dim.
• Electric starter sounds weak.
• Battery has not been used for an extended period of time.

Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

1. Perform a voltmeter test to determine the state of charge. If battery needs to be charged, proceed to the next step.

Remove battery from motorcycle before charging. Electrolyte leakage will damage motorcycle parts. (00213a)

2. Remove the battery from the motorcycle. See Battery: Blast Models.

3. Place the battery on a level surface.

Unplug or turn OFF battery charger before connecting charger cables to battery. Connecting cables with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00066a)

Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

Do not reverse the charger connections described in the following steps or the charging system of the motorcycle could be damaged. (00214a)

NOTES:

• The figures listed in the Amp-hour table assume that the battery is charging at room temperature. If warmer than room temperature, use a slightly shorter charging time. If colder, use a slightly longer charging time.
• The use of constant current chargers to charge sealed maintenance free batteries is not recommended. Any overcharge will cause dry-out and premature battery failure. If a constant current charger is the only type available, do not exceed the charge times listed in 12 Amp-Hour Battery Charging Rates and Times and do not continue charging the battery if it gets hot. When charging, never exceed 15 volts.

4. Connect the red battery charger lead to positive (+) terminal of the battery.

5. Connect the black battery charger lead to negative (-) terminal of the battery.

NOTE:


If the battery is still in the vehicle, connect the negative lead to the chassis ground. Make sure that the ignition and all electrical accessories are turned off.

6. Step away from the battery and turn on the charger.

Unplug or turn OFF battery charger before disconnecting charger cables from battery. Disconnecting clamps with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00067a)

7. After the battery is fully charged, turn OFF the charger and disconnect the black battery charger lead to the negative (-) terminal of the battery.

8. Disconnect the red battery charger lead to the positive (+) terminal of the battery.

9. Mark the charging date on the battery.

12 Amp-Hour Battery Charging Rates and Times

Storage

Turn engine over a few times to be sure there is no oil in the crankcase and that all oil has been pumped back into the oil tank. Stop engine and re-check oil level. Failure to do so can result in engine damage. (00071a)

Do not allow battery to completely discharge. The electrolyte in a discharged battery will freeze. The more discharged a battery is, the more easily it can freeze and crack the battery case. (00218a)

If the motorcycle will not be operated for several months, such as during the winter season, remove the battery from the motorcycle and fully charge.

If the motorcycle is to be stored with the battery installed, it will be necessary to connect a battery tender to maintain charge. See an authorized dealer for more information.

Self-discharge is a normal condition and occurs continuously. The rate of self-discharge depends on the ambient temperature and the battery's state of charge.

• Batteries discharge at a faster rate at higher ambient temperatures.
• To reduce the self-discharge rate, store battery in a cool (not freezing), dry place.
• Charge the battery every month if stored at temperatures below 60° F. (16° C).
• Charge the battery more frequently if stored in a warm area above 60° F. (16° C).

Capacity Months of stand Measured at 105 degrees F Measured at 77 degrees F Effective Rate of Temperature on Battery Self-discharging Rate

Battery: Blast Models

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Disconnection and Removal

1. Remove seat. See Seat: Blast Models.

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

2. Loosen bolt and remove battery negative cable (black) from battery negative (-) terminal.

3. Loosen bolt and remove battery positive cable (red) from battery positive (+) terminal.

Installation and Connection

Unplug or turn OFF battery charger before connecting charger cables to battery. Connecting cables with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00066a)

1. Place the fully charged battery into the battery box with the terminal side to the rear of the motorcycle, facing upwards.

Be sure jumper cables touch only appropriate battery terminals or ground. Allowing jumper cables to touch each other can result in sparks and a battery explosion, which could result in death or serious injury. (00072a)

Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

2. Insert bolt through battery positive cable (red) into threaded hole of battery positive (+) terminal.

3. Tighten bolt to 72-96 in-lbs (8.0-10.9 Nm).

4. Insert bolt through battery negative cable (black) into threaded hole of battery negative (-) terminal.

5. Tighten bolt to 72-96 in-lbs (8.0-10.9 Nm).

6. Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals.

After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

7. Install seat.

Jump-Starting Buell Motorcycles

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Buell does not recommend jump-starting a motorcycle. However, there may be circumstances when it is necessary to do so. Therefore, we suggest jump-starting be performed as follows:

Be sure jumper cables touch only appropriate battery terminals or ground. Allowing jumper cables to touch each other can result in sparks and a battery explosion, which could result in death or serious injury. (00072a)

Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

Buell motorcycles have a 12 Volt battery. Be sure the booster vehicle has a 12 Volt system. Failure to do so could result in vehicle damage. (00242a)

1. Turn off all unnecessary lamps and accessories.

Positive Cable

2. See Jump Start Cable Connections. Connect one end of a jumper cable to the DISCHARGED battery positive (+) terminal (1).

3. Connect the other end of the same cable to the BOOSTER battery positive (+) terminal (2).

Negative Cable

Do not connect negative (-) cable to or near the discharged battery negative (-) terminal. Doing so could cause a spark and explosion, which could result in death or serious injury. (00073a)

4. Connect one end of a jumper cable to the BOOSTER battery negative (-) terminal (3).

Do not connect the negative (-) cable to painted or chrome parts. Doing so could result in discoloration at the attachment point. (00221a)

5. Connect other end of the same cable to a safe ground (4), (away from the DISCHARGED battery).

6. Start motorcycle.

7. Disconnect cables in reverse order of steps 2, 3, 4, 5. That is: steps 5, 4, 3, 2.

Discharged battery positive (+) terminal Booster battery positive (+) terminal Booster battery negative (-) terminal Ground Jump Start Cable Connections

Electrical Protection: Blast Models

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General

To protect the motorcycle's electrical components from overload, your Blast uses a fuse block and a main circuit breaker.

For electrical problems, it is best to see a Buell dealer. They have the necessary parts and equipment to perform electrical services.

Fuse Block

The fuse block, located under the seat on the right side, contains five replaceable fuses and a slot to hold one spare fuse. A label near the fuse block indicates the function of each fuse (lighting, key switch, system, spare, ignition and accessory).

Lamps fuse Key switch fuse System fuse Spare Ignition fuse Accessory fuse Fuse Location: Blast Models (right side under seat)

Main Circuit Breaker

The main circuit breaker is located behind the battery. The main circuit breaker is self-resetting and automatically returns steady power to the circuit when an electrical fault that causes it to trip is found and corrected. If the electrical fault is not found and corrected, the breaker will cycle on and off causing the motorcycle to operate erratically and eventually the battery will lose its charge.

Storage: Blast Models

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Proper storage is important for the trouble-free operation of your motorcycle. See your Owner's Manual for storage recommendations or see a Buell dealer. Improper storage procedures can lead to equipment damage. (00128a)

If the motorcycle will not be operated for several months, such as during the winter season, follow the procedure below. Proper storage preparation will protect parts against corrosion, preserve the battery and to prevent the build-up of gum and varnish in the fuel system. Improper storage may adversely effect the warranty. See Warranty and Service Information: Buell Models for more information.

List everything you do and fasten it to a handlebar. When you take the motorcycle out of storage, this list will be your reference/checklist to get your motorcycle in operating condition.

Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00003a)

Placing Motorcycle in Storage

1. Warm motorcycle to operating temperature. Change oil and turn engine over to circulate the new oil.

2. Fill fuel tank and add a gasoline stabilizer. Use one of the commercially available gasoline stabilizers and follow the manufacturer's instructions.

3. Run the engine until the gasoline stabilizer has had a chance to reach the carburetor float bowl.

4. Turn fuel supply valve OFF.

5. Check rear drive belt wear.

6. Check tire inflation. Adjust to proper inflation pressure.

7. Wash and polish molded-in-color, painted and chrome surfaces.

8. See Battery: General for proper battery care. Remove battery from the motorcycle and charge. Store the battery above freezing temperatures and trickle charge once a month.

Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

If motorcycle is to be covered, use a material such as light canvas that will breathe. Plastic materials that do not breathe promote the formation of condensation which can damage the finish of the motorcycle. (00247a)

Removal From Storage

The clutch failing to disengage can cause loss of control, which could result in death or serious injury. Prior to starting after extended periods of storage, place transmission in gear and push vehicle back and forth several times to assure proper clutch disengagement. (00075a)

1. Install charged battery.

2. Remove and inspect the spark plug. See service manual.

3. Clean the air cleaner filter element.

4. Check amount of oil in the oil tank (cold check). Check the transmission lubricant level.

5. Start the engine and run until it reaches normal operating temperature. Turn engine and ignition/headlamp key switch off.

6. Check engine oil level (hot check).

7. Check controls to be sure they are operating properly. Operate the front and rear brakes, throttle control, clutch lever and gear shift lever.

8. Check steering for smoothness by turning the handlebars through the full operating range.

Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Buell dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00114a)

9. Check for correct tire pressure. Incorrect tire pressure will result in poor riding characteristics and can effect handling and stability.

10. Check all electrical equipment, switches, headlamp, stop lamp, turn signals and horn for proper operation.

11. Check for any fuel, oil or brake fluid leaks.

Turn engine over a few times to be sure there is no oil in the crankcase and that all oil has been pumped back into the oil tank. Stop engine and re-check oil level. Failure to do so can result in engine damage. (00071a)