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.
|forks seal kit||All-Balls Racing – 56 – 126|
|fork bushes kit||All-Balls Racing – 38 – 6053|
|taper roller headstock bearings||All-Balls Racing – 22 – 1026|
|rear master cylinder seal kit||All-Balls Racing – 18 – 1079|
|rear caliper seal kit||All-Balls Racing – 18 – 3050|
|front caliper seal kit||All-Balls Racing – 18 – 3047|
|brembo front pads||carbon ceramic 07BB04.CC|
|brembo rear pads||carbon ceramic 07BB02.CC|
|braided hose kit||hel performance HBF0881|
|rear wheel spoke nipples||8 gauge / 7.6mm barrel|
|Side Panels||ufo YZ 125 / 250 (96-01) – remove air scoops|
|Fork Protectors||ufo all CR / CRF|
|rear mudguard/fender||ufo YZ 125 / 250 (98-02) – cut required|
|led rear light||polisport RSP LED 3.0|
|front forks||WP 4357 MXMA – google for service manual|
|front wheel bearings||2 – 60042RS|
|rear wheel bearings||2 – 60042RS + 1 62042RS|
|swinging arm||my 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 nipples||M10 x 1mm|
|Fork cap o-ring*||46810016 – 48 x 2mm|
|Fork slider snap ring*||43570099 – 53 x 2mm|
|ktm fork guard bolts||59001092050|
|ktm foot rest springs||54603041000|
|ktm foot rest pins||54603044000|
|front master cylinder||yamaha yzf r125 brembo – requires m10 x 1 to m10 x 1.25 adapter – hel performance H8153132C|
|Bearings||refer to pictures in engine bearing section – all koyo – except 3|
* additonal parts to complete fork rebuild on top of All-Balls Racing kits