and so it starts!

I needed a project to keep me sane after selling the GSXR. Just didn’t realise that it was going to be a complete rebuild.

So what is a CCM 644 DS, well basically its a bitza. CCM built the frame and swinging arm then used parts from several different manufacturers, Brembo brakes, WP suspension, Suzuki XF650 engine, plastics from Yamaha and Honda. You could think of it as an uprated DR650. The DS part stands for dual sport, so many came with offroad and supermoto wheels.

Note: My bike is in supermoto trim, so some parts may vary.

Info on CCMs is a bit hit and miss, as was their build quality, so I’m documenting everything I use for future reference. You don’t have to use these parts, but it will give you a starting point. When searching for chassis parts I generally start looking at early 2000 ktm 250 exc stuff.

PartItem Identified
forks seal kitAll-Balls Racing – 56 – 126
fork bushes kitAll-Balls Racing – 38 – 6053
taper roller headstock bearingsAll-Balls Racing – 22 – 1026
rear master cylinder seal kitAll-Balls Racing – 18 – 1079
rear caliper seal kitAll-Balls Racing – 18 – 3050
front caliper seal kitAll-Balls Racing – 18 – 3047
brembo front padscarbon ceramic 07BB04.CC
brembo rear padscarbon ceramic 07BB02.CC
braided hose kithel performance HBF0881
rear wheel spoke nipples8 gauge / 7.6mm barrel
Side Panelsufo YZ 125 / 250 (96-01) – remove air scoops
Fork Protectorsufo all CR / CRF
rear mudguard/fenderufo YZ 125 / 250 (98-02) – cut required
led rear lightpolisport RSP LED 3.0
front forksWP 4357 MXMA – google for service manual
front wheel bearings2 – 60042RS
rear wheel bearings2 – 60042RS + 1 62042RS
swinging armmy choice –
2 – HK2016.2RS-MB bearings each side plus 1 SD20X26X4A-INA seal, time will tell if this works, but its better than stock
caliper bleed nipplesM10 x 1mm
Fork cap o-ring*46810016 – 48 x 2mm
Fork slider snap ring*43570099 – 53 x 2mm
ktm fork guard bolts59001092050
ktm foot rest springs54603041000
ktm foot rest pins54603044000
front master cylinderyamaha yzf r125 brembo – requires m10 x 1 to m10 x 1.25 adapter – hel performance H8153132C
Bearingsrefer to pictures in engine bearing section – all koyo – except 3
163/22
26209CM
3suzuki 09262-22028
46004rscm
563052rscm
662032rscm
76208CM
86204cm

* additonal parts to complete fork rebuild on top of All-Balls Racing kits