Abstract/ Develop an engine that would fit into a smaller, entry-level sport bike (the Buell Blast) intended to attract new riders to the sport of motorcycling. Challenge/ Appeal to new riders who want an aggressive design but not the weight that comes with a larger bike. Design a 492cc air-cooled, single-cylinder engine. Ensure that the engine can be manufactured on the same production line as Harley-Davidson's 1200cc dual-cylinder Sportster engine and share some combustion components. Solution/ Innovative, integrated chassis mounting. Low-cost, lightweight, noise-reducing polymer pushrod tube system that is aesthetically distinct from Harley-Davidson products. All-new oiling and primary drive systems. Lightweight, optimally balanced crankshaft system, later adopted for other Harley-Davidson crankshafts. Created single-cylinder crankcase, top cover, primary cover, and gearcover that incorporate a distinctive appearance, cost reduction initiatives, and the utilization of existing components and manufacturing processes. Results/ First year production of the Buell Blast sold out in three months. Buell Blast has become a major contributor to Harley-Davidson's efforts to introduce motorcycling to younger riders. Read about Harley and their attempts to attract younger riders and buyers in the April 23, 2007 Milwaukee Journal Sentinel