Buell 500 Blast (2002-2009): The Unconventional Beginner’s Companion Revisited

Introduction

The Buell Blast 500 occupies a peculiar space in motorcycle history—a machine born from Harley-Davidson’s experimental subsidiary, Buell, designed to be an affordable entry point for new riders. Produced from 2002 to 2009, this air-cooled single-cylinder oddball polarized opinions during its tenure. Some dismissed it as underpowered and crude; others praised its simplicity and approachable character. After spending time with this quirky American lightweight, it’s clear the Blast deserves a closer look—not as a performance icon, but as a charming, no-nonsense machine that prioritizes rider engagement over brute force.

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Design & Ergonomics: Function Over Flair

The Blast’s aesthetic is unmistakably Buell, blending industrial pragmatism with subtle aggression. The HSLA steel backbone frame—painted in titanium gray—dominates the visual profile, doubling as an oil reservoir to reduce component clutter. It’s a clever piece of engineering that gives the bike a lean, almost skeletal appearance. Bodywork is minimal, with a petite fuel tank (10.6 liters / 2.8 US gallons) and a solo seat that hints at its urban mobility focus.

Ergonomically, the Blast shines. The seat height adjusts between 648–775 mm (25.5–30.5 inches), accommodating riders of varying statures. Even at its tallest setting, the narrow frame and 163 kg (360 lbs) dry weight make footing manageable. Handlebars are upright and wide, promoting a relaxed posture ideal for city commutes. However, the bench-style seat firms up during extended rides—a common complaint that aftermarket cushioning can easily resolve.

Color options evolved yearly, ranging from subdued Midnight Black to vibrant Sunfire Yellow. Our test bike’s Arctic White scheme with silver wheels felt fresh, accentuating the minimalist design.

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Engine Performance: Single-Cylinder Soul

At the Blast’s heart lies a 492cc air-cooled single-cylinder mill, producing 34 HP at 6,500 RPM and 40.7–46 Nm (30–33.9 lb-ft) of torque. These figures seem modest, but the engine’s personality defies spreadsheets. Thumb the electric starter, and the OHV 2-valve motor settles into a lumpy idle—a reminder of its Harley-Davidson Sportster lineage (the block shares DNA with Harley’s XR750).

Twist the throttle, and torque arrives immediately. Peak torque hits as low as 3,200 RPM, propelling the Blast off the line with eagerness. While vibrations intensify past 5,000 RPM, the Uniplanar™ powertrain isolation system—a Buell hallmark—dulls high-frequency buzz without neutering feedback. The carbureted fueling (Keihin 40mm in later models) delivers crisp response, though cold starts occasionally demand patience.

The 5-speed transmission pairs with a belt final drive (excluding a chain-driven 2006 variant). Shifts are clunky but precise, rewarding deliberate lever action. Top speed hovers around 145 km/h (90 mph), making highway rides feasible but breathless. This isn’t a bike for conquering continents—it’s a backroad companion that thrives where speeds stay below 100 km/h (62 mph).

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Handling & Ride Experience: Lightweight Agility

Weighing just 181 kg (400 lbs) wet, the Blast dances through traffic. The 1,397 mm (55-inch) wheelbase and 25-degree rake strike a balance between stability and flickability. Showa underpinnings—37 mm forks up front and a gas-charged shock out back—offer 115 mm (4.5 inches) and 104 mm (4.1 inches) of travel, respectively. Suspension is non-adjustable and softly tuned, absorbing potholes competently while wallowing during aggressive cornering.

Tire sizes (100/80-16 front, 120/80-16 rear) skew toward neutrality, delivering predictable grip. Braking evolved across generations: early models used dual front discs, later transitioning to a single 220 mm rotor. Our 2007 tester’s single-disc setup provided adequate stopping power, though aftermarket pads improve bite.

The riding experience is raw and mechanical. Wind blast punishes riders at speed, and the exhaust’s muted thump won’t turn heads. Yet, there’s joy in its transparency—every input feels direct, every adjustment intuitive. It’s a bike that rewards skill without intimidating novices.

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Competition: Underdog in a Crowded Arena

The Blast’s era pitted it against Japanese and European entry-level staples:

• Kawasaki Ninja 250: Smoother parallel-twin engine, sportier styling, but heavier and less torque-rich at low RPM.
• Suzuki GS500: Twin-cylinder flexibility and higher top speed, yet plagued by dated ergonomics and heft.
• Honda Rebel 300: Fuel-injected modernity and lower seat height, albeit with less character.

Where the Blast carves its niche is in tactile engagement. Competitors prioritize refinement; the Buell offers a visceral, unapologetic ride. The belt drive eliminates chain maintenance, and its steel frame feels sturdier than budget commuters. However, its air-cooled engine and carburetor demand more hands-on care than fuel-injected rivals.

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Maintenance: Keeping the Blast Alive

Ownership requires embracing simplicity:
1. Carburetor Care: Clean jets annually—ethanol-blended fuels clog passages. Consider upgrading to a Mikuni VM34 for crisper response.
2. Belt Inspections: Check for cracks or fraying every 5,000 km (3,100 miles). Replacements are straightforward with MOTOPARTS.store’s aftermarket kits.
3. Oil Changes: The dry-sump system holds 1.9 liters (2 quarts). Use 20W50 mineral oil for optimal heat dissipation.
4. Valve Adjustments: Easy access via OHV covers; check every 8,000 km (5,000 miles).

Common upgrades include:
- Aftermarket Exhaust: Unleash the single’s bark with a slip-on muffler.
- Gel Seat: Alleviates numbing on long rides.
- Handlebar Risers: Improves ergonomics for taller riders.

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Conclusion: A Cult Classic Reassessed

The Buell Blast 500 isn’t perfect—it’s buzzy, underpowered, and spartan. Yet, these “flaws” define its charm. In an era dominated by disposable commuters, the Blast feels alive, demanding involvement and rewarding patience. For new riders seeking a machine that teaches mechanics as much as riding skills, or veterans craving unadulterated simplicity, this underdog remains compelling.

At MOTOPARTS.store, we celebrate motorcycles with soul—and the Blast has it in spades. Explore our catalog for parts that keep your Buell thriving, from performance carburetors to ergonomic upgrades. Ride slow, ride often, and let the Blast remind you why motorcycling is about connection, not just speed.

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Specifications sheet

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