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404 tech info & part numbers: alternative parts, bearing/seal sizes, etc.

DonkeyBike
Baron
Joined: September 5th, 2013, 1:00 pm

December 22nd, 2013, 12:07 pm #1

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

internal front wheel bearing spacer for 404ds dimensions:
Length 54mm
external width 28mm
internal width 20mm
wall thickness 6mm

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FCR Carb: 13200-29F10 superseded by 13200-29FF0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
Front forks are WP MXMA 4860 and rear suspension is WP PDS 5018
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 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.



Last edited by DonkeyBike on July 30th, 2018, 7:53 pm, edited 33 times in total.
CCM404DS@AdvIrl.com
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DonkeyBike
Baron
Joined: September 5th, 2013, 1:00 pm

January 4th, 2014, 2:08 am #2

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... wrote: 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)


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

Last edited by DonkeyBike on February 10th, 2014, 1:09 am, edited 4 times in total.
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stevo604
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Joined: February 25th, 2012, 5:57 pm

January 4th, 2014, 2:47 pm #3

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
Baron
Joined: September 5th, 2013, 1:00 pm

September 18th, 2015, 12:58 am #4

Front and Rear brake pad part numbers added to the first post. ?
Last edited by DonkeyBike on November 2nd, 2015, 4:33 pm, edited 1 time in total.
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kito
Knight
kito
Knight
Joined: June 20th, 2014, 1:51 pm

June 8th, 2016, 11:26 am #5

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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Joined: January 30th, 2012, 6:02 pm

June 8th, 2016, 4:48 pm #6

kito wrote: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
Knight
kito
Knight
Joined: June 20th, 2014, 1:51 pm

June 9th, 2016, 6:26 pm #7

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
God
Joined: January 31st, 2012, 10:39 am

June 9th, 2016, 7:43 pm #8

Done.
Dunno how that Dr350 shit got on there.
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 :(
HUSKY FE501 missile

Mid Wales trail guide for hire: click Sweetlamb Facebook or www.adventurerallybike.co.uk


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DonkeyBike
Baron
Joined: September 5th, 2013, 1:00 pm

June 30th, 2016, 4:08 pm #9

Rob 110 wrote: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-Spro ... 1903815619


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


Daithi.
Last edited by DonkeyBike on August 27th, 2016, 10:54 am, edited 1 time in total.
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Angustoyou
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Angustoyou
Commoner
Joined: April 30th, 2012, 6:10 pm

January 29th, 2017, 6:12 pm #10

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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