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404 tech info & part numbers: alternative parts, bearing/seal sizes, etc.
Topic Started: Dec 22 2013, 12:07 PM (6,881 Views)
DonkeyBike
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DonkeyBiker
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I was thinking about putting together the manufacturers part numbers for every part used on the 404, plastics, electrics, switches, bearings, seals, wheels, suspension etc. It might take ages though, very handy to have. It would be useful if someone else did the same with the other models of CCM and had a list of alternative sources and part numbers for the CCM parts.


WHEELS
CCM404DS Bearing & Seal sizes
Rear hub BEARING: 2x 6004-2RS required & 1x 6204-2RS
Front hub BEARING - 2x 6004-2RS required
Seals: Front: 2off: 24x42x8 Rear: 1off 25x47x7 & 1off 24x42x8
Front Brake Pad: EBC FA181-TT
Rear Brake Pad: EBC FA208
For CCM 404 E / DS

ENGINE
Output Shaft Seal: 30 X 40 X 6 09283-30053
Gear Lever Seal:
Clutch shaft Seal: 10 X 20 X 6.
Clutch shaft Bearing: 12 X 16 X 10.
FCR Carb: 13200-29F10 superseded by 13200-29FF0



BODY PARTS
Replacement saddle: '96- 01 yz 250.
Front Mudguard: KTM Part No: 590.01093100
Rear Mudguard: Yamaha YZ 125-250__'96-'02 (needs cutting where it joins onto the CDI tray).
Rad. Shrouds: Honda CRF 450__'03
RHS Panel: Yamaha YZ 125-250__'96-'02
LHS Panel: Yamaha YZ 125-250__'96-'02 (left side panel needs some trimming).
Fork guards are KTM WP fork type.


FRAME & SUSPENSION
Chain guide: KX85
Chain slipper: cr125
Fork Seals: Be careful here, not as straight forward as you might think, I'd suggest
removing old ones to confirm...
Needle Bearings for Shock: ??
Front Sprocket: Suzuki DRZ400: Jt sprockets JTF432SC
Rear Sprocket: Same as Suzuki DR350S or CCM644 on spoked wheels or Husqvarna: JT sprockets JTR822 / JTA822
Steering Head Bearing: AS109 = L45449
404 foot pegs are same as 2001 Suzuki RM250
Switch Gear: GasGas EC (afaik)

ELECTRICAL
Spark Plug: NGK CR8EK or CR8E or CR8EIX (the suffix "IX" represents Iridium)
Battery: YT7B - BS

Warning, contrary to suggestions the YTX12A-BS is physically too big to fit in the battery holder.



Edited by DonkeyBike, Feb 1 2017, 03:14 PM.
CCM404DS@AdvIrl.com
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DonkeyBike
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DonkeyBiker
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I intend adding to the first post until it's as complete and accurate as possible, if you have any information to add or correct the above please reply and I'll modify the first post.

This second post will contain specs/dimensions specific to the CCM404:
"TopEnd of engine..."
 

The cylinder head bolts get tightened to 18 foot pounds (25 N-M, 2.5 kgf-m) first in an X pattern, then tighten again to 33.5 foot pounds (46 N-M, 4.6 kgf-m). The bolts and nuts on the outside of the head get torqued to 7 foot pounds (10 N-M, 1.0 kgf-m). The cylinder head side bolt, if you removed it, gets tightened to 10 foot pounds (14 N-M, 1.4 kgf-m). The camshaft journal holder bolts get tightened to 7 foot pounds (10 N-M, 1.0 kgf-m). And finally, the valve cover gets 7 foot pounds initially, then 10 the second time around.

Valve clearance is;
Intake: 0.10~0.20mm (0.0039~0.0079 in)
Exhaust: 0.20~0.30mm (0.0079~0.0118 in)

Posted Image

http://dwulet.com/bikes/docs/Torque_DRZ400S.PDF

Edited by DonkeyBike, Feb 10 2014, 01:09 AM.
CCM404DS@AdvIrl.com
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stevo604
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God
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you have hit the nail on the head their.it would be handy for the 404 604 and the 644 and made as a sticky for parts references as a whole lot of people would be asking what fit this and that.good speek :worthy:
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DonkeyBike
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DonkeyBiker
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Front and Rear brake pad part numbers added to the first post. 😎
Edited by DonkeyBike, Nov 2 2015, 04:33 PM.
CCM404DS@AdvIrl.com
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kito
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Can anyone confirm what rear sprocket fits the 404 ? I just ordered a dr350s rear sprocket and the bolting circle is 10mm to small. I'm not interested in the aluminium sprockets as I already have a talon on and want to replace it
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Monty
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kito
Jun 8 2016, 11:26 AM
Can anyone confirm what rear sprocket fits the 404 ? I just ordered a dr350s rear sprocket and the bolting circle is 10mm to small. I'm not interested in the aluminium sprockets as I already have a talon on and want to replace it
same as the 644, as same wheels
If it aint sharp I can play with it
My Utube Channel, lots of bike vids here. Subscribe if you likehttp://www.youtube.com/user/choppermark?feature=watch

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kito
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Can the moderators please correct the list so others don't buy the DR350s sprocket that does NOT fit. I ordered a JT sprocket JTR822-47
JTR822-48 ect does fit.
Thanks kito
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Rob 110
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Done.
Dunno how that Dr350 shit got on there.
CLICK HERE TO DONATE TO THE FORUM

DIRTY R30 644 '03 TPS done, gubbins gone, GSXR can, 150 main, 27.5 pilot, needle 2nd position, K&N no lid
FILTHY 404DS '04: 152 main, 70 pilot air jet, 38 pilot, emm needle 4th clip, Quill T3. Sold :(
BIGBORE STRIMMER: KTM 300 EXCE '08 Rally
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DonkeyBike
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DonkeyBiker
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Rob 110
Jun 9 2016, 07:43 PM
Done.
Dunno how that Dr350 shit got on there.


I put that "SHIT" there Rob, I've ordered, received and fitted a rear sprocket for the DR350S three or four times now and they are the
same part, it must however be the DR350S.

The ebay link below lists the JT 48T Rear Sprocket 520 for Suzuki DR350S 1990-1993 as part number JTR822-48 as described by Kito


http://www.ebay.ie/itm/JT-48T-Rear-Sprocket-520-for-Suzuki-DR350S-1990-1993-/321903815619


If I'm mistaken let me know.....


Daithi.
Edited by DonkeyBike, Aug 27 2016, 10:54 AM.
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Angustoyou
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The 404Ds battery is NOT as listed above, that one is physically too large for the holder. The correct battery is YT7B - BS
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DonkeyBike
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Angustoyou
Jan 29 2017, 06:12 PM
The 404Ds battery is NOT as listed above, that one is physically too large for the holder. The correct battery is YT7B - BS
Thanks Angus, first post corrected... :bye:
CCM404DS@AdvIrl.com
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Walshy
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Front brake and clutch levers? I'm gonna buy some fancy ones but don't want to go universal. Any ideas guys?
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Rob 110
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Front is pre 2003 ktm. Can't remember clutch
CLICK HERE TO DONATE TO THE FORUM

DIRTY R30 644 '03 TPS done, gubbins gone, GSXR can, 150 main, 27.5 pilot, needle 2nd position, K&N no lid
FILTHY 404DS '04: 152 main, 70 pilot air jet, 38 pilot, emm needle 4th clip, Quill T3. Sold :(
BIGBORE STRIMMER: KTM 300 EXCE '08 Rally
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Walshy
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Cheers rob maybe someone else will post the clutch :dirtbike:
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jamie96
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i know this is an old thread but do replacement clutch levers come with the two plastic shims ?
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Walshy
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King
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Mine didn't mate
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rwxalas
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Front forks are WP MXMA 4860 and rear suspension is WP PDS 5018
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Kernow
Kernow
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Any idea what silencers fit , the oval scorpion would be ok if I could find one , mine still has the heavy round one fitted.
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