OWNERS MANUAL &

WARRANTY
 GP450
OWNER’S MANUAL
1st edition, April 2014
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
CCM Motorcycles
is expressly prohibited.

March 2016
Introduction
Congratulations on your choice of CCM motorcycle.

Please take the time to read this owner’s manual thoroughly as it will not only inform you how to operate the motorcycle and its various controls but also
how to maintain and care for your motorcycle in line with the CCM warranty package.

It also contains important information on how to make the best of the motorcycles technical features and accessories.

In addition, many tips are given on how to keep the motorcycle in its best possible condition.

If you have any question concerning your motorcycle your nearest CCM dealer will gladly provide advice and assistance.

We hope you enjoy your new CCM and all of your journeys are safe.

Note:
This Owner's Manual is a valuable document. Please keep it safe, as it will be required in connection with servicing and any warranty claim that may
arise. This manual should be transferred to the new owner if the motorcycle is sold.

The high safety standards of CCM motorcycles are maintained by constant development of designs, equipment and accessories. Due to this, your
motorcycle may differ from the information supplied in this manual. CCM also cannot entirely rule out errors and omissions. We hope you can appreciate
that no claims can be entertained on the basis of the data, illustrations or descriptions in this manual.

March 2016
Motorcycle/Dealer details

March 2016
Table of Contents
1. Description
Left side view ....................................... 1-1
Right side view..................................... 1-2
2. Instruments and Controls
Instrument Panel.................................. 2-1
Main switch/steering lock ..................... 2-4
Handlebar switches ............................. 2-5
3. Pre-operation checks
Pre-operation checklist ........................ 3-1
4. Important riding points
Safety instructions ............................... 4-1
Starting the engine............................... 4-2
Engine revs.......................................... 4-2
Running in ........................................... 4-2
Off-road riding ...................................... 4-2
Refuelling your motorcycle ................... 4-3
Loading the motorcycle ........................ 4-3
Rear luggage rack ............................... 4-3
Tool Kit ................................................ 4-4
5. Periodic Maintenance
Periodic maintenance chart.................. 5-1
Checking engine oil ............................. 5-3
Replacing engine oil and filter .............. 5-4
Removing seat ..................................... 5-5
Braking system .................................... 5-5
Coolant ................................................ 5-6
Clutch .................................................. 5-6 Tightening torque figures ..................... 8-8
Wheels and tyres ................................. 5-7
Drive chain........................................... 5-7 9. Service
Rear shock absorber............................ 5-8 Confirmation of maintenance work ....... 9-1
Front suspension ................................. 5-9
Rear linkage system ............................ 5-10
Bulbs ................................................... 5-10
Air filter ................................................ 5-11 10. Warranty Booklet
Battery ................................................. 5-11
Fuses................................................... 5-11
Troubleshooting ................................... 5-12
6. Motorcycle care
Cleaning your motorcycle..................... 6-1
Motorcycle storage............................... 6-2
7. Accessories
8. Technical data
Engine ................................................. 8-1
Fuel ..................................................... 8-1
Engine oil ............................................. 8-2
Clutch .................................................. 8-2
Transmission ....................................... 8-3
Final drive ............................................ 8-3
Front suspension ................................. 8-3
Rear suspension .................................. 8-4
Brakes ................................................. 8-4
Wheels and tyres ................................. 8-5
Tyre pressures ..................................... 8-5
Electrics ............................................... 8-6
Chassis ................................................ 8-7
Dimensions .......................................... 8-7
Weights ............................................... 8-7
March 2016
 1. Description

Left side view

1. Fuel cap
2. Engine oil filter housing
3. Oil drain bolt and strainers
4. Shift pedal
5. Battery (under seat)

1-1
 2. Instrument and Controls

Right side view

1. Rear carrier
2. Rear brake fluid reservoir
3. Front brake fluid reservoir
4. Rear brake pedal
5. Engine oil level window
6. Engine oil filler cap

2-1

Instrument panel
DIGITAL DASHBOARD, WARNING
LIGHTS
The motorcycle is fitted with a digital
instrument on which 5 warning lights are
also available: high beam lights, low beam
lights (with display lighting), turning
indicators, neutral gear and fuel reserve.
1 - BLUE warning light “High beam”
2 - GREEN warning light ”Low beam”
3 - GREEN warning light “Turning
indicators”
4 - GREEN warning light “Neutral”
5 - ORANGE warning light “Fuel reserve”
Note:
- After engine starts, the dashboard shows
the SW version for the 2 seconds; after
the check routine, the dashboard shows
the last planned function.
- When the engine is turned off, the
dashboard does not show any functions.
- To select instrument functions and reset
functions, use the SCROLL button (A)
2. Instrument and Controls
- Available functions are listed below in the 1) set to figure 1, place the ignition key in
order they appear when selecting the OFF position and push the knob
them. SCROLL (A);
2) place the ignition key in the ON position
1 - SPEED / ODO while pressing the SCROLL wheel for 3
2 - SPEED / H seconds (A)
3 - SPEED / CLOCK To confirm the conversion, “SET” and the
4 - SPEED / TRIP 1 Miles and mph or km and kmh segments 2
5 - SPEED / STP 1 will activate for 3 seconds; display will
6 - SPEED / AVS 1 then go back to the standard function
7 - SPEED / MAX SPEED shown in Fig.1.
8 - SPEED / TRIP 2
9 - SPEED / TRP 2 / CLOCK Note:
10 -SPEED After the previously described operation,
the ODO setting will be converted
and all other data reset (the H Counter is
unchanged).
1- SPEED (kmh or mph) / ODO (figure 1)
- SPEED: vehicle speed - maximum value: 2- SPEED / H (figure 2)
299 kmh or 299mph;
- ODO: odometer- maximum value: 99999 - SPEED: speed - maximum value: 299
km or 62136.5 mi; kmh or 299mph;
To change unit from kilometres to miles - H: shows the engine running hours (data
or miles to kilometres, proceed as are saved to permanent memory
follows: every 10 minutes).
- Maximum value: 9999:59;
2-1

3- SPEED / CLOCK (figure 3)
- SPEED: speed - maximum value: 299
kmh or 299mph;
- CLOCK: Clock- reading from 0:00 to
23:59:59 (data will be lost after
disconnecting
the battery).
To reset the clock, push the SCROLL
button (A) and hold for more than 3
seconds
in order to increase the hour value; release
button and after 3 seconds
the minutes can be increased;
4- SPEED / TRIP 1 (figure 4)
- SPEED: speed - maximum value: 299
kmh or 299 mph;
- TRIP 1: distance - maximum value: 999.9
km or 621,31 mi (data will be lost
after disconnecting the battery).
Resetting the STP 1 also resets the TRIP 1
and AVS 1 data.
The function TRIP 1 is ON together with
the function STP 1 (*).
2-3
2. Instruments and Controls
5- SPEED / STP 1 (figure 5)
- SPEED: speed - maximum value: 299
kmh or 299mph;
- STP 1: miles/kilometres covered time
- Reading from 0:00 to 23:59:59 (data will
be lost after disconnecting the
battery).
To activate the function STP 1, push the
SCROLL button (A) and hold for
more than 3 seconds.
- 1st step: activate function;
- 2nd step: stop counters.
- 3rd step: reset STP 1, TRIP 1 and AVS
1 data;
- 4th step: activate function;
- 5th step: stop counters.
and so on
Note:
STP 1 data+TRIP 1 data=AVS 1 (*).
 2. Instruments and Controls
7- SPEED / V MAX (figure 7)

- SPEED: speed - maximum value: 299

kmh or 299mph;
- V MAX: Shows the maximum speed
reached by the vehicle, in kmh or
mph.

Maximum value: 299 kmh or 299 mph. To 2

set to zero V MAX, push the knob
SCROLL (A) for more than 3 seconds;

6- SPEED / AVS 1 (figure 6) 9- TRP 2 / CLOCK (figure 9)

- SPEED: speed - maximum value: 299 - TRIP 2: distance - maximum value: 999.9
kmh or 299 mph; km/miles (data will be lost after
- AVS 1: shows the average vehicle speed, disconnecting the battery);
according to covered distance
To reset TRIP 2, push the SCROLL button
(TRIP 1) and time (STP1) (data will be lost (A) and hold for more than 3 seconds;
after disconnecting the battery).
- CLOCK: Clock- reading from 0:00 to
NOTE: Resetting the STP 1 also resets the 23:59:59 (data will be lost after
TRIP 1 and AVS 1 data. disconnecting
8- SPEED / TRIP 2 (figure 8) the battery).

- SPEED: speed - maximum value: 299
kmh or 299 mph;
- TRIP 2: distance - maximum value: 999.9
km/miles (data will be lost after
disconnecting the battery);
To reset the clock, push the knob SCROLL
(A) for more than 3 seconds in order
to increase the hours; release the knob
then, after 3 seconds, it is possible
to increase the minutes;

To reset TRIP 2, push the SCROLL button

(A) and hold for more than 3 seconds;

2-3

Main switch/steering lock
2. Instruments and Controls
The steering is locked, and all electrical
systems are off. The key can be removed.
To lock the steering
1. Turn the handlebars all the way to the left
or right.
2. Push the key in from the “OFF” position,
and then turn it to “LOCK” while still 2
pushing it.
3. Remove the key.

To unlock the steering

10- SPEED (figure 10) Push the key into the main switch, and then
turn it to “OFF” while still pushing it.
- SPEED: speed - maximum value: 299
kmh or 299 mph; WARNING!
Never turn the key to “OFF” or
The main switch/steering lock controls the “LOCK” while the vehicle is moving.
ignition and lighting systems, and is used to Otherwise the electrical systems will be
lock the steering. The various positions are switched off, which may result in loss of
described below. control or an accident.
ON
All electrical circuits are supplied with
power; the meter lighting, taillights, license
plate light and auxiliary lights come on, and
the engine can be started.
The key cannot be removed.

Note:
The headlights come on automatically when
the engine is started and stay on until the
key is turned to “OFF”.

OFF
All electrical systems are off. The key can
be removed.
LOCK

2-4
 2. Instruments and Controls
Handlebar switches indicator (the GREEN tell-tale signal 2. Engine start
will flash on the dash unit). - Press the engine start button to
- Press the turn signal control to the activate the engines starter motor
right to illuminate the right signal and crank the engine over.
indicator (the GREEN tell-tale signal
will flash on the dash unit).
- To cancel the indicator, press the
control switch in whilst in a central 2
position (the GREEN tell-tale signal
will stop flashing in the dash unit and
signal indicators will be cancelled).

4. Horn
- Push the horn button to active the
Left handlebar switch
audible horn (horn will activate until
1. Passing light
button is released).
- Depress the passing light switch to
temporarily illuminate the high-beam
headlight.

2. High-beam/low-beam control
- Depress the beam control button to
illuminate the high-beam headlight
(the button will remain depressed
while the high-beam is illuminated
and the BLUE tell-tale warning
illuminates on the dash unit ).
- Press the beam control button again
to revert to the low-beam setting.
Right handlebar switch
1. Engine kill switch
3. Turn signal indicator
- Press the kill switch to cut the
- Press the turn signal control to the
engine. The ignition system will
left to illuminate the left signal
remain active but the engine will not
continue to run.

2-5
 3. Pre-operational Checks
Pre-operational checklist Clutch:
(See section 5-6)
- Check clutch lever free play. Adjust if necessary.
The following items should be checked before every ride to
- Check the clutch cable for damage or fraying. Replace if
ensure the motorcycle will function correctly:
necessary.
Chain:
(See section 5-7)
- Check chain tension. No more than 10mm of slack should be
Throttle: 3
- Check the throttle cable free play. Adjust if necessary.
present.
- Check the throttle cable for signs of damage or fraying. Replace
- Check chain condition.
if necessary.
Brakes:
(See section 5-5)
Fuel:
- Check front and rear brake fluid levels. Top up if low.
- Ensure fuel level in tank is sufficient.
- Check front and rear brake pads for signs of wear or damage.
Replace if necessary.
Engine oil:
- Check for a spongy feel on front or rear brake lever/pedal.
(See section 5-3)
Bleed brake system if necessary.
- Ensure oil level in engine is correct. Top up if low.
Tyres: - Check vehicle for oil leaks. If signs of leaking fluid are seen do
(See section 5-7) not ride the motorcycle and seek professional advice from a
- Visually inspect tyres for splits or damage. Replace if certified dealer.
necessary.
Coolant:
- Check tyre tread level is sufficient for the type of riding about to
(See section 5-6)
be done.
- Check coolant level in radiator. Top up if low.
- Check tyre pressures are in line with the recommended
- Check vehicle for signs of coolant leaks. If signs of leaking fluid
pressures.
are seen do not ride the motorcycle and seek professional
Wheels: advice from a certified dealer.
(See section 5-7)
Bodywork fixings:
- Inspect front and rear wheel rims for splits, cracks or dints.
- Check security of all bodywork fixings and fasteners.
Replace if necessary.
- Check front and rear wheel spokes are tensioned correctly. Lights and instruments:
- Check rear wheel alignment is set correctly. Adjust if necessary. - Check function of all electrical systems to ensure they are
functioning correctly.

4-1
 4. Important Riding Points
Safety instructions Correct loading For this reason, observe the following
Overloading and imbalanced loads can points: Do not run the fuel tank dry.
adversely affect the motorcycle's handling. Stop the engine immediately if it misfires.
Rider's equipment Do not exceed the permissible gross weight Use only unleaded fuel.
Do not ride without the correct clothing. and be sure to comply with the instructions Comply with all specified maintenance
Always wear: on loading. intervals.
- Helmet Unburned fuel will destroy the catalytic
- Motorcycling jacket converter.
Alcohol and drugs 4
- Trousers
Even small amounts of alcohol or drugs will
- Gloves
adversely affect your perception and your Risk of fire
- Boots
ability to assess situations and make Temperatures at the exhaust are high.
This applies even to short journeys, and to
decisions, and slow down your reflexes. Flammable materials (e.g. hay, leaves,
every season of the year.
Medication can exacerbate these effects. grass, clothing and luggage, etc.) could
Do not ride your motorcycle after ignite if allowed to come into contact with
Speed consuming alcohol, drugs and/or the hot exhaust pipe. Do not permit
If you ride at high speed, always bear in medication. flammable materials to come into contact
mind that various boundary conditions can with the hot exhaust system.
adversely affect the handling of your Cooling would be inadequate if the engine
Risk of poisoning
motorcycle: were allowed to idle for a lengthy period
Exhaust fumes contain carbon monoxide,
- Settings of the spring-strut and with the motorcycle at a standstill:
which is colourless and odourless but highly
shock-absorber system overheating would result. In extreme cases,
toxic. Inhaling the exhaust fumes therefore
- Imbalanced load the motorcycle could catch fire.
represents a health hazard and can even
- Loose clothing Do not allow the engine to idle for an
cause loss of consciousness with fatal
- Insufficient tyre pressure unnecessary length of time
consequences. Do not inhale exhaust
- Poor tyre tread
fumes. Do not run the engine in an
- Etc.
enclosed space.

Maximum speeds for tyres

High voltage
The motorcycle's top speed might be higher
Touching live parts of the ignition system
than the maximum speed permitted for the
with the engine running can cause electric
tyres. Excessive speeds can damage the
shock. Do not touch parts of the ignition
tyres and this could cause accidents.
system when the engine is running.
Comply with the tyre-specific speed
restrictions.
Catalytic converter
If misfiring causes unburned fuel to enter
the catalytic converter, there is a danger of
overheating and damage.

4-1

Starting the engine
To start the engine,
- Turn on the ignition switch.
- Ensure the motorcycle is in neutral
or the clutch lever is pulled in.
- Press the starter button and hold
until the motorcycle starts (a small
opening of the throttle may be
necessary due to external factors
such as temperature).
Note:
Do not hold the start button down for
more than 5 seconds continuously.
During a bump start it is necessary to
hold the start button in order to keep the
ECU live.
Engine revs
When started from cold, allow the
motorcycle a moment to warm up and for oil
to properly circulate within the engine
before revving/riding the motorcycle. When
riding, avoid high engine speeds until the
engine reaches proper operating
temperature.
Prolonged riding with the engine revving at
speeds in excess of 8000 rpm can lead to
engine damage. Avoid revving the engine
to speeds in excess of 8000 rpm.
Your motorcycle is not designed for
extended periods of revving at engine
speeds in excess of 8000 rpm. Riding with
the engine revving at speeds in excess of
8000 rpm can result in damage and engine-
revolution excursions above this limit are
logged in the control unit's memory.
CCM refuses to accept liability for engine
damage if engine-revolution excursions
above this limit are stored in the control
unit's memory.
Gear-to-speed table for 8000 rpm and
standard final drive transmission ratio:
1st gear: 30 mph
2nd gear: 45 mph
3rd gear: 55 mph
4th gear: 75 mph
5th gear: 90 mph
Running in
(First 500 miles)
While running in the motorcycle, vary the
throttle opening and engine-speed range
frequently. Avoid maintaining constant
engine speeds over lengthy periods and
accelerating to the rpm limit.
Maximum speeds during running-in
Period ≤75 mph (in 5th gear)
Have the first inspection performed after
500 miles.
Brake pads
New brake pads have to bed down before
they can achieve their optimum friction
levels. You can compensate for this initial
4-3
4. Important Riding Points
reduction in braking efficiency by exerting
greater pressure on the levers.
New brake pads can extend stopping
distance by a significant margin.
Apply the brakes in good time.
Tyres
New tyres have a smooth surface. This 4
must be roughened by riding in a restrained
manner at various lean angles until the
tyres are run in. This running in procedure
is essential if the tyres are to achieve
maximum grip. Tyres do not have their full
grip when new and there is a risk of
accidents at extreme angles of lean.
Avoid extreme angles of lean.
Off-road riding
Tyre pressure
Tyre pressures reduced for off-road riding
impair the motorcycle's handling
characteristics on surfaced roads and can
lead to accidents. Always check that the
tyre pressures are correct.
Wheel rims for off-road riding
CCM recommends checking the rims for
damage after off-roading.
Dirt or mud on brakes
When riding on loose surfaces or muddy
roads, the brakes may fail to take effect
immediately because of dirt or moisture on
the discs or brake pads.
Apply the brakes in good time until the
brakes have been cleaned.

The brake pads will wear more rapidly if
you ride frequently on un-surfaced tracks or
poor roads. Check the thickness of the
brake pads more frequently and replace the
brake pads in good time.
Refuelling
Fuel is highly flammable. A
naked flame close to the fuel
tank can cause a fire or explosion.
Do not smoke. Never bring a naked
flame near the fuel tank.
Fuel expands when hot. Fuel escaping
from an overfilled tank could make its
way onto the rear tyre. This could cause
a fall.
Do not fill the tank past the bottom edge
of the filler neck. Fuel attacks plastics,
which become dull or unsightly.
Wipe off plastic parts immediately if they
come into contact with fuel.
Leaded fuel will destroy the catalytic
converter. Use only unleaded fuel.
Make sure the ground is level and firm
and place the motorcycle on its stand.
4. Important Riding Points
Loading the extreme rear of the
motorcycle with a lot of weight
can adversely affect the motorcycles
handling.
Never exceed the motorcycles maximum
gross weight (see section 8-7)
4
Rear luggage rack
When loading the rear luggage rack do not
exceed the maximum carrying capacity.
To open the fuel tank cap
Open the fuel tank cap lock cover (1), insert Always ensure the load is properly secured
the key into the lock (2), and then turn it 1/4 and mounted as far forward as possible.
turn counter-clockwise. The lock will be
released and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into position with
the key inserted in the lock.
2. Turn the key clockwise to the original
position, remove it, and then close the
lock cover.
Loading the motorcycle
Always use caution when loading luggage The carrying capacity of the rear luggage
onto the motorcycle. rack can be increased to 15 kg when the
universal rear rack is fitted as this provides
Ensure the weight is evenly distributed additional support.
between the left and right sides and the
weight is as close to the centre of the
motorcycle as possible.
4-3
 4. Important Riding Points
Tool Kit With this tool kit a minimum of the following
procedures can be carried out:

 Suspension adjustment
 Front fuel tank removal
 Top cowl removal
 Seat removal
 Screen removal 4
 Radiator guard removal
 Battery removal
 Fuse access
 Air filter access
 Lighting bulb replacement
 Front brake fluid reservoir access
The standard tool kit features the following
items:

 4mm Hex key

 4mm Ball ended hex key
 5mm Hex key
 Size 5 Flat screwdriver
 Size 1 Philips screwdriver
 Size 2 Phillips screwdriver
 Round bit (rear shock
adjustment)

The tool kit is a single piece unit with the

various removable heads located within the
handle of the tool.

4-3
 5. Periodic Maintenance

Periodic maintenance chart

 The annual checks below must be performed every year unless a mileage based service is performed instead.
 From 20000 miles repeat the 5000 mile maintenance intervals.
 Items marked with an asterisk should be performed by an approved dealer as special technical skills are required.
5
Odometer Reading (Miles) Annual
No. Item Work to be carried out
Check
500 5000 10000 15000 20000
1 * Fuel line Check fuel hoses for cracks or damage P P P P P
Check condition
P P P P P
2 Spark Plug Clean and regap
Replace P P
Check clearance
3 * Valves P P P P
Adjust
4 * Fuel injection Adjust engine idle speed P P P P P P
5 Muffler and exhaust Check clamps for looseness P P P P P P
Clean P P P P
6 Air filter element
Replace P P
Check operation
7 Clutch P P P P P
Adjust
Check operation, fluid level and signs of fluid leakage P P P P P P
8 * Front brake
Replace brake pads Whenever worn to the limit
Check operation, fluid level and signs of fluid leakage P P P P P P
9 * Rear brake
Replace brake pads Whenever worn to the limit
Check for cracks or damage P P P P P
10 * Brake hoses
Replace Every 6 years
Check runout, spoke tightness and rim damage
11 * Wheels P P P P
Tighten spokes if necessary

5-1
 5. Periodic Maintenance

Check tread depth and condition

12 Tyres Check tyre pressures P P P P P P
Check sidewalls for splits or damage
13 * Wheel bearings Check bearings for play or damage P P P P
14 * Swingarm Check smoothness of operation and for excessive play P P P P
Check chain slack
Every 500 miles and after cleaning the motorcycle or riding in the 5
15 Drive chain Check rear wheel allignment
rain
Clean and lubricate
16 Chain sliders Inspect chain slider pads for signs of wear P P P P
Check bearing play or roughness P P P P P
17 * Steering bearings
Lubricate bearings with lithium soap based grease P P
18 Fasteners Ensure security of all nuts, bolts and fasteners P P P P P P
Check operation
19 Sidestand P P P P P
Lubricate pivot
Check operation and signs of fluid leakage P P P P
20 Front forks
Replace oil P
21 Rear shock absorber Check operation and for signs of oil leakage P P P P
Check operation for smoothness and exsesive play
22 Rear linkage assembly P P P P
Clean bearings and journals
Check for signs of oil leakage
23 Engine oil P P P P P P
Replace oil
24 Engine oil filter Replace P P P P P P
25 Pivots and cables Lubricate P P P P P
Check operation
26 Lights and electrics P P P P P P
Set headlight beam
Check coolant level and for signs of leakage P P P P P
27 Cooling system
Replace coolant Every 3 Years

5-1
 5. Periodic Maintenance
Checking engine oil If the engine oil level is too high, have the
oil level corrected by an authorised CCM
dealer.
**CCM recommends Motul 5100 10/40 4T
oil**
To top up engine oil, ensure ground is flat
The engine can seize if the oil level is low, and level.
and this can lead to accidents.
5
Always make sure that the oil level is
correct. The oil level varies with the
temperature of the oil. The higher the
temperature, the higher the level of oil in
the sump. Checking the oil level with the
engine cold or after no more than a short
ride will lead to misinterpretation; this in Check the oil in the oil level inspection
turn, means that the engine will be operated window (1)
with the incorrect quantity of oil.

In order to ensure that the engine oil level is

read correctly, check the oil level only after - Remove oil filler cap (1).
a lengthy trip or sufficient engine warming. - Top up oil to specified level on the
Allow the engine to idle until the fan starts inspection window.
up then allow it to idle one minute longer. - Re-fit filler cap and wipe any excess
Switch off the engine. oil away using a cloth.
- Always check for signs of leaks after
Make sure the engine is at operating performing an oil change and do not
temperature and hold the motorcycle ride the motorcycle if anything is
upright. seen.
Ensure the oil level is between the
maximum and minimum marks.

If the engine oil level is too low, top up with

clean oil.

5-3
 5. Periodic Maintenance
Replacing engine oil and - Fill the engine with the specified
amount of engine oil.
filter - Run the engine until the fan kicks in
then for a further one minute to
- Start the engine and run it until ensure it is at the correct operating
operating temperature is reached in temperature.
order to thin the oil. - Check the oil level in the inspection
- Place the motorcycle on its side window and adjust if necessary. 5
stand with a drain pan underneath - Always check for signs of leaks after
the oil sump plug. performing an oil change and do not
ride the motorcycle if anything is
- Once most of the oil is drained seen.
remove the 2 oil strainers (1) and
inspect for debris, clean if
necessary.

- Remove the oil sump plug (1) and

allow oil to drain into drain pan.
- Beware engine oil will be hot.

- Remove the oil filter cover (1) and oil

filter element.
- Fit a new oil filter element and
replace the filter cover.
- Replace the 2 oil strainers and oil
sump plug.

5-4

Removing seat
To remove the motorcycle seat;
- Remove the M6 bolt fitted through
the rear tank.
- Slide the seat backwards away from
its locating plates.
- When refitting the seat ensure the
location plates are correctly
positioned.
Braking system
Checking operation of brakes
- Pull the handbrake lever.
- The pressure point must be clearly
perceptible.
5. Periodic Maintenance
- Press the footbrake lever.
- The pressure point must be clearly
perceptible.
No clearly perceptible pressure point:
Bleed the brake circuit and check the brake
system for damage.
5
Checking brake pad thickness
Brake pads worn past the minimum
permissible thickness can cause a
reduction in braking efficiency and under
certain circumstances they can cause - Check the fluid level in the front
damage to the brake system. brake master cylinder (1) is above
In order to ensure the dependability of the the minimum marker.
brake system, do not permit the brake pads
to wear past the minimum permissible
thickness.
Visually inspect the condition and thickness
of the brake pad friction material.
Minimum material thickness not
including backing plate: 1.6mm
Checking brake-fluid level
A low fluid level in the brake reservoir can
allow air to penetrate the brake system.
This significantly reduces braking efficiency.
Check the brake-fluid level at regular - Check the fluid level in the rear
intervals. master cylinder is above the
- Make sure the ground is flat and minimum marker.
level and hold the motorcycle
vertical. The standard brake fluid is DOT4,
- Turn the handle bars to a straight however in hot climates or for intense
ahead position. brake use DOT5.1 is recommended.
5-5
 5. Periodic Maintenance
Coolant Clutch
Checking operation of clutch
Risk of burns from escaping
coolant! - Pull in the clutch lever.
The hot cooling system is pressurised. - The pressure point must be clearly
Allow the coolant to cool down before perceptible.
opening the radiator cap. - If it is not, have the clutch checked
by an approved CCM workshop. 5
- Make sure the ground is flat and
level and hold the motorcycle
vertical.
Checking clutch lever play
- Check the coolant level in the
radiator is correct.

Coolant, specified level

Antifreeze
Top plates just covered by
coolant (MIN level)
4 mm (MAX level, covering
the top plates)
- Once the radiator has cooled,
remove the cap (1) by turning it - Pull in clutch lever until resistance is
counter-clockwise. felt.
- If coolant level is too low, top up to
- Measure clutch lever play (a)
correct level.
Recommended clutch lever play:
1mm
- If clutch lever play is out of tolerance
turn the adjuster (1) until clutch play
is correct.

5-5

Wheels and tyres
Checking tyre tread depth
Your motorcycle's handling and grip can be
impaired even before the tyres wear to the
minimum tyre tread depth permitted by law.
Have the tyres changed in good time before
they wear to the minimum permissible tread
depth.
- Make sure the ground is level and
firm and place the motorcycle on its
stand.
- Measure the tyre tread depth in the
main tread grooves with wear marks.
Tyres have wear indicators integrated into
the main tread grooves. The tyre is worn
out when the tyre tread has worn down to
the level of the marks. The locations of the
marks are indicated on the edge of the tyre,
e.g. by the letters TI, TWI or by an arrow.
- If the tyre tread is worn to minimum:
replace tyre or tyres, as applicable.
Checking wheel rims
- Make sure the ground is level and
firm and place the motorcycle on its
stand.
- Visually inspect the rims for defects.
Have damaged rims checked and, if
necessary, replaced by a specialist
workshop.
Checking spokes
- Make sure the ground is level and
firm and place the motorcycle on its
stand.
- Draw the handle of a screwdriver or
a similar instrument across the
spokes and listen to the notes of the
individual spokes.
If the notes vary:
Have the spokes checked by a specialist
workshop.
Drive Chain
Lubricating chain
Dirt, dust and inadequate lubrication will
result in accelerated wear and
significantly shorten the drive chain's
useful life.
Clean and lubricate the drive chain at
regular intervals.
- Lubricate the drive chain every five
hundred miles at the latest.
- Lubricate the chain more frequently
if the motorcycle is ridden in wet,
dusty or dirty conditions.
- Switch the ignition off and select
neutral.
- Clean the drive chain with a suitable
cleaning product, dry it and apply
chain lubricant.
- Wipe off excess lubricant.
5-7
5. Periodic Maintenance
Checking chain slack
If the chain is slack there will be more chain
noise and the chain will wear more rapidly.
Excessive chain slack may also result in
damage to the swingarm and other
components.
The design of the motorcycle permits it to 5
be ridden with slight chain sag. It is
important to ensure that chain sag is to
specification.
- Turn the rear wheel until it reaches
the position with the lowest amount
of chain sag.
- Use a screwdriver to push the chain
up and down and measure
difference (1).
- If the chain is out of the specified
range, slacken the rear wheel nut
and use the chain adjuster bolts to
tighten then re-tighten the rear wheel
nut and adjuster lock nuts.
Drive chain slack:
5-10mm

Rear shock absorber
Adjusting the spring preload
The spring preload is fundamental for the
function of the suspension. If the preload is
set incorrectly, all further adjustments will
not enable you to get the intended
performance from the suspension.
The rear spring preload is adjusted using
the upper spring retainer collar.
- Loosen the locking screw (1) with a
2.5mm hex key (max 2 turns)
- Use a 5mm hex hey inserted into the
holes in the collar (2) to rotate the
collar.
- Rotate clockwise to increase preload
and counter-clockwise to decrease
spring preload.
- 1 complete revolution of the collar is
equal to an adjustment of 1.5mm in
spring preload.
- After adjusting the spring preload be
sure to tighten the locking screw (1).
Adjusting the compression damping
Compression damping controls the energy
absorption when the shock absorber is
being compressed. The rear shock has 2
compression controls called LS (low speed)
and HS (high speed).
Compression damping adjuster
Turn the hexagon (or screw) adjusters on
the reservoir part (1 & 2) with a 4mm hex
key.
Turn clockwise to increase damping and
turn counter clockwise to decrease it.
If the shock absorber speed is low, adjust
the LS knob, for example if the shock
movement is initially too hard or too soft to
provide enough comfort.
If you encounter damping problems
whereby the shock feels too soft or hard
when driving over a pothole, adjust the HS
knob.
5-9
5. Periodic Maintenance
Reset the adjuster
Turn the adjuster clockwise to fully closed
position. Then, turn counter clockwise to
open it. First click open is position zero
(0). Count the clicks until you reach the
recommended number of clicks.
Do not use force when you
reach the end of the adjustment 5
range as delicate parts can be damaged.
Also avoid using a lot of force between
clicks.
Adjusting the rebound damping
Rebound damping controls the energy
absorption when the shock absorber is
being extended and controls how fast the
shock absorber returns to its normal
position after being compressed.
Rebound damping adjuster
Turn the hexagon (or screw) adjuster on the
end of the piston rod part (1) with a 4mm
hex key.
 5. Periodic Maintenance
Turn clockwise to increase damping and Front Suspension Adjusting the compression damping
turn counter-clockwise to decrease it.
Reset the adjuster
Turn the adjuster clockwise to fully closed Adjusting the fork preload
position. Then, turn counter clockwise to
open it. First click open is position zero
(0). Count the clicks until you reach the
recommended number of clicks.
5
Do not use force when you reach
the end of the adjustment range
as delicate parts can be damaged. Also
avoid using a lot of force between clicks.

Compression damping controls the energy

Standard shock settings absorption when the shock absorber is
being compressed.
19mm (8mm on The spring preload is fundamental for the
Spring preload
lowered version) function of the suspension. If the preload is The compression damping is adjusted
set incorrectly, all further adjustments will using a flat blade screw driver (1).
10 clicks (11 on
Rebound damping not enable you to get the intended
lowered version) - To increase spring preload turn the
performance from the suspension.
adjuster clockwise
Compression 10 clicks (11 on The front fork preload is adjusted using the - To decrease spring preload turn the
damping (HS) lowered version) 19mm hex adjuster (2). adjuster counter-clockwise.
Compression 10 clicks (11 on
damping (LS) lowered version) - To increase spring preload turn the Reset the adjuster
adjuster clockwise Turn the adjuster clockwise to fully closed
- To decrease spring preload turn the position. Then, turn counter clockwise to
adjuster counter-clockwise. open it. First click open is position zero
Do not open the nitrogen filling
(0). Count the clicks until you reach the
plug. Special charging tools and
recommended number of clicks.
access to nitrogen is required to fill the Periodically remove the cross head
shock with pressure again. screw (1) to release the pressure in the Do not use force when you
fork cartridge. reach the end of the adjustment
range as delicate parts can be
damaged. Also avoid using a lot of
force between clicks.

5-9
 5. Periodic Maintenance
Adjusting the rebound damping Standard fork settings
Spring preload 0mm
17 clicks (17 on
Rebound damping
lowered version)
Compression 24 clicks (24 on
damping lowered version)
5

Rear linkage system

Rebound damping controls the energy
absorption when the fork leg is being
extended and controls how fast the fork leg
returns to its normal position after being
compressed.
The rebound damping is adjusted using a
flat blade screw driver (3).
- To increase spring preload turn the
adjuster clockwise
- To decrease spring preload turn the
adjuster counter-clockwise.
Reset the adjuster
Turn the adjuster clockwise to fully closed
position. Then, turn counter clockwise to
open it. First click open is position zero
(0). Count the clicks until you reach the
recommended number of clicks.
Do not use force when you
reach the end of the
adjustment range as delicate parts can
be damaged. Also avoid using a lot of
force between clicks.
The rear linkage on this motorcycle features
lightweight polymer bearings.
These bearings do not require
lubrication as they are self-lubricating.
Periodically remove the rear linkage
assembly (1) to inspect its condition.
5-11
Remove the journals (2) and thoroughly
clean the journal faces and any mating
bearing faces.
Do not remove the bearings from
the housing unless new bearings
are being fitted.
Bulbs
A defective bulb places your safety at risk
because it is easier for other users to
oversee the motorcycle. Replace defective
bulbs as soon as possible. The types of
bulb fitted to your motorcycle are listed in
the section entitled "Technical data".
Do not touch the glass of new bulbs with
your fingers. Use a clean, dry cloth to hold
the bulbs when handling them. Dirt
deposits, in particular oil and grease,
interfere with heat radiation from the bulb.
This leads to overheating and shortens the
bulb's operating life.

Air filter
The air filter element should be replaced at
the intervals specified in the periodic
maintenance chart. Replace the air filter
element more frequently if you are riding in
unusually wet or dusty areas.
To replace the air filter element;
- Remove the right side fuel tank.
- Remove the two securing clips (1)
by lifting them up.
- Slide the lower half of the airbox out
to the right side of the motorcycle.
5. Periodic Maintenance
- Pull apart the two securing tabs (1) Fuses
to allow the filter frame (2) to be
lifted out of the lower airbox casing.
- Clean or replace the foam filter The motorcycle is equipped with two fuses.
element (3).
- Refit the air filter element and
securing frame by pressing it firmly,
ensuring the locating clips are
properly located. 5
- Refit the lower airbox into the
motorcycle and secure using the two
external casing clips.
- Refit the fuel tank.
Battery
This motorcycle uses a high performance The lighting fuse (10 A) can be located
lithium battery as standard. inside the top cowl behind the dash unit.
Do not use a conventional battery
charger with this battery as it
could cause damage to the battery. Use
only a lithium specific battery charger.
The batteries charge state can be tested by
holding the TEST button on top of the
battery.
Due to the nature of lithium batteries, when
you first attempt to start the motorcycle it
may occasionally seem like the battery is
flat. In this case, continue pressing the The main fuse (30 A) can be located under
starter button and the battery will supply the motorcycle seat.
increasing power levels with each attempt
until the motorcycle starts.
5-11

Troubleshooting
The following list can be used to
troubleshoot and find the necessary
remedies.
The engine does not start.
- Faulty starter motor: repair or
replace.
- Faulty starter relay: replace.
- Blown main fuse: replace.
- Faulty start button: replace the
switch.
- Dirty or worn out spark plug: clean or
replace.
- Insufficient fuel in tank: top up petrol
tank.
- Battery flat: charge or replace
battery. (note special battery
instructions on page 5-11)
The engine does not easily start.
- Dirty spark plug: clean or replace.
- Incorrect spark plug gap: adjust gap.
The engine overheats.
- Airflow to the radiator is blocked:
clean radiator.
- Cooling fan not operating: replace
fan relay and/or coolant sensor.
- Insufficient coolant level in radiator:
once cooled, top up coolant.
- Insufficient quantity of engine oil: top
up oil.
5. Periodic Maintenance
The engine lacks power. - Brake fluid leaking: inspect for leaks
and replace or repair where
- Dirty air filter: clean or replace. necessary.
- Spark plug electrode gap too large: - Brake disc worn or damaged:
adjust gap. replace disc.
- Incorrect valve clearances: adjust
- Insufficient compression: check for
cause.
5
The alternator fails to charge or its
charge is insufficient.
- Connectors to the regulator or
alternator are badly connected:
connect correctly or replace.
- Faulty alternator coil: replace.
- Demagnetised alternator rotor:
replace.
- Faulty voltage regulator: replace.
The battery overheats.
- Faulty voltage regulator: replace.
Difficulty shifting gears.
- Incorrect viscosity of engine oil used:
replace with correct grade of oil.
The clutch slips.
- Clutch plates worn out: replace
clutch plates.
- Insufficient spring force: replace
springs.
- Clutch cable poorly adjusted: adjust.
Faulty/under-powered brakes.
- Brake pads worn out: replace.
- Brake fluid levels low: top up fluid.
- Brake fluid old/dirty: replace fluid.
5-11

Cleaning Your Motorcycle
Proper and frequent cleaning is a vital part
of correctly maintaining your motorcycle.
The nature and design of motorcycles leads
to many parts being exposed to the
elements, making them much more
vulnerable to rust and corrosion.
Proper cleaning is important, not only to
comply with the motorcycles warranty but
also to keep your motorcycle looking good
and extending its life.
Before cleaning
- Cover the muffler outlet with a
plastic bag or specific exhaust bung
(after the motorcycle has cooled
down) to stop any water or moisture
entering the exhaust system.
- Ensure that all caps, covers and
electrical connectors are tightly and
properly installed.
- Remove very stubborn dirt such as
oils or chain lubricants using a
degreasing agent and brush. Never
apply these agents to any seals,
bearings, gaskets, sprockets, drive
chain or the wheel axles. Always
ensure the degreasing agent and dirt
is fully rinsed off with water.
After normal use
Remove dirt with warm water, a mild
detergent and a soft, clean sponge then
rinse thoroughly with clean water.
Use a toothbrush or similar to get into any
hard to reach areas.
After riding in the rain or on salt-sprayed
roads
Road salt is extremely corrosive in
combination with water. After each ride in
the rain or on salt-sprayed road the
following steps should be carried out.
- Clean the motorcycle with COLD
water and a mild detergent after the
motorcycle has cooled down.
- Apply a corrosion protection spray to
all metal parts to prevent corrosion.
Note:
Never use warm water as it increases
the corrosive action of the road salt.
After cleaning
- Thoroughly dry the motorcycle using
a chamois or absorbent cloth.
- Immediately dry and lubricate the
drive chain to prevent it from rusting.
- Always ensure the motorcycle is fully
dry before covering.
6-1
6. Motorcycle Care
WARNING
 Avoid using strong acidic wheel
cleaners as they can greatly
increase corrosion. If such
products are used, thoroughly
rinse off with water. Dry the area
immediately and apply a
corrosion protection spray. 6
 Improper cleaning can damage
plastic parts such as fuel tanks,
cowlings and windscreens. Use
only a soft cloth or sponge on
these areas and clean water.
 Do not use any harsh chemical
products on plastic areas. Be sure
not to use cloths or sponges that
have been in contact with any
abrasive or solvent based
cleaners.
 Do not use strong cleaners or
hard sponges on the motorcycles
windscreen as this area can easily
discolour or scratch leading to an
impaired view of the road.
 Avoid the use of high powered
pressure washers as delicate
parts and electrics can be
damaged.
 6. Motorcycle Care
Motorcycle Storage Returning the motorcycle to service
Before attempting to ride the motorcycle
Short term
after a long period of storage:
Always store your motorcycle in a cool, dry
 Remove any protective grease
place and if necessary, protect it against
applied.
dust with a porous cover. Always ensure
the motorcycle is dry and the engine has  Thoroughly clean the motorcycle.
fully cooled before covering.  Remove any exhaust muffler 6
covers.
 Check condition of battery and
install a charged battery if
Long term
necessary.
Before storing your motorcycle for an  Work through the pre-operational
extended period of time: checklist before attempting to
start or ride the motorcycle.
 Thoroughly clean the motorcycle.
 Lubricate the brake and clutch lever
pivots along with the side and main
stand pivots.
 Lubricate any control cables.
 Coat any bright metal parts in acid-
free grease (e.g. Vaseline).
 Drain the motorcycle fuel tanks.
 Remove the battery or connect it to
the lithium battery optimizer.
 Cover muffler outlet with a plastic
bag to stop moisture entering.
 Stand the motorcycle in a room in
such a way that there is no weight
on either the front or rear wheel to
prevent tyre damage during storage
(use a box type stand).

6-2
 7. Accessories
Accessories
Please refer to accessories downloads on
www.ccm-motorcycles.com for up to date
information on all accessory installation and
usage guidelines.

7-1
 8. Technical Data
Engine
Engine design Single-cylinder four-stroke, double overhead camshafts,
4 valves, two operated by bucket tappets
and two by cam followers, liquid-cooled cylinder
and cylinder head, integral coolant pump, 5-speed
gearbox.
Displacement 449.5 cm3 8
Cylinder bore 98 mm
Piston stroke 59.6 mm
Compression ratio 12 : 1
Idle speed 1850 - 1950 RPM

Fuel
Recommended fuel grade Premium unleaded gasoline only
Usable fuel capacity Approx. 20 litres
Rear tank 10 litres
Front LH tank: 5 litres
Front RH tank: 5 litres

8-1
 8. Technical Data
Engine Oil

Oil consumption max 0.1 l/h

Engine oil, capacity max 1.15 l, with filter change
Engine oils, Permissible viscosity classes and products 8
Motul 5100 SAE 10W-40 ≥-20 °C
Oil grades Semi-synthetic engine oils of API classification SF to SH.
CCM recommends not using oil additives, because they can
have a detrimental effect on clutch operation. Please do not
hesitate to contact your authorised CCM dealer if you have
any questions relating to the choice of a suitable engine oil
for your motorcycle.

Permissible viscosity classes

SAE 5 W-40 ≥-30 °C, Operation at low temperatures

SAE 10 W-40 ≥-20 °C, Operation at low temperatures
SAE 15 W-40 ≥-10 °C

Clutch
Clutch type Multi-plate clutch running in oil bath

8-2
 8. Technical Data
Transmission
Gearbox type Claw-shift 5-speed gearbox, integrated into engine
block
Gearbox transmission ratios 2,618, Primary transmission ratio
2.462 (13:32 teeth), 1st gear
1.706 (17:29 teeth), 2nd gear
1.350 (20:27 teeth), 3rd gear 8
1.043 (23:24 teeth), 4th gear
0.880 (25:22 teeth), 5th gear

Final Drive
Type of final drive Chain drive
Final drive, number of teeth (Pinion / sprocket) 15 / 47

Front Suspension
Type of front suspension 45mm upside-down telescopic fork
Available adjustment Spring preload,
Rebound damping
Compression damping
Suspension travel 265mm wheel travel (165mm lowered version)
Factory Pre load settings 0mm (0mm on lowered version)
Factory adjustment settings Rebound damping: 17 clicks (17 on lowered version)
(All adjustments are from fully closed clockwise position. Zero Compression: 24 clicks (24 on lowered version)
position is on first click turning anti-clockwise).

8-5
 8. Technical Data

Rear Suspension
Type of rear suspension Central spring strut with coil spring and linkage mount
Available adjustment Spring preload,
Rebound damping 8
High speed compression damping
Low speed compression damping
Suspension travel 265mm wheel travel (165mm lowered version)
Factory pre-load settings (95Nmm and 100Nmm springs) 19mm (8mm lowered version)
Factory adjustment settings Rebound damping: 10 clicks (11 on lowered version)
(All adjustments are from fully closed clockwise position. Zero High speed compression: 10 clicks (11 on lowered version)
position is on first click turning anti-clockwise). Low speed compression: 10 clicks (11 on lowered version)
Brakes
Front
Brake disc type 320mm single floating disc
Brake calliper type Twin piston floating calliper
Operation Hand operated
Recommended fluid Normal use: DOT 4
Hot climate/intense use: DOT5.1

Rear
Brake disc type 220mm fixed single disc
Brake calliper type Single piston floating calliper
Operation Foot operated
Recommended fluid Normal use: DOT 4
Hot climate/intense use: DOT5.1

8-5
 8. Technical Data

Wheels and Tyres

Front
Wheel type Spoke wheel
Rim size 1.6”x21” 8
Tyre type Tubed
Tyre size 90/90-21 (54T)
Tyre model Dunlop Trailmax

Rear
Wheel type Spoke wheel
Rim size 2.15”x18”
Tyre type Tubed
Tyre size 120/90-18 (65T)
Tyre model Dunlop Trailmax

Tyre Pressures
Front
Normal conditions 200 kPa (2.0 kgf/cm2, 29 psi)
Off-road riding 125 kPa (1.85 kgf/cm2, 18 psi)
Luggage and/or pillion 215 kPa (2.15 kgf/cm2, 31 psi)

Rear
Normal conditions 215 kPa (2.15 kgf/cm2, 31 psi)
Off-road riding 125 kPa (1.85 kgf/cm2, 18 psi)
Luggage and/or pillion 235 kPa (2.35 kgf/cm2, 34 psi)

8-5
 8. Technical Data
Electrics
Fuses

Main fuse 30 A
Fuse for lighting system 10 A
8
Battery

Battery designation HJTZ7S-FP-SWI

Battery type High-performance lithium
Battery rated voltage 12 V
Battery rated capacity 2.4 Ah

Spark Plug

Spark plugs, manufacturer and designation NGK CR 9 EKB

Electrode gap of spark plug 0.8±0.1 mm, When new

Lighting

Bulb for low-beam and high-beam headlight H4 halogen 12 V 60/55 W

Bulb for side light 12 V 5W
Bulb for tail light/brake light LED 12V
Bulbs for flashing turn indicators 12 V 10 W

8-6
 8. Technical Data
Chassis
Chassis type Aluminium bonded modular frame with bolt in side braces and
rear subframe
VIN location Headstock, right

8
Dimensions
Overall length 2170mm
Overall height 1475mm (1375mm lowered version)
Seat height 890mm (790mm lowered version)
Wheelbase 1510mm
Ground clearance 360mm (260mm lowered version)

Weights
Dry weight 125.5 kg
Unladen weight (ready for road with 90% fuel) 141 kg
Permissible gross weight 335 kg
Maximum payload 194 kg
Rear rack maximum loading 5 kg (15 kg with universal rear rack fitted)

8-8
 8. Technical Data
Tightening torque figures
Item Setting Note
Front wheel spindle nut 50 Nm
Front wheel spindle clamp bolts 12 Nm
Front brake calliper fixing bolts 25 Nm
8
Front brake disc 12 Nm Install using Loctite 243
Rear wheel spindle nut 80 Nm
Swingarm semi-spindle 75 Nm Ensure specific spanner is used to hold
inside of journal to avoid frame damage
Rear sprocket 30 Nm Install using Loctite 243
Rear brake disc 12 Nm Install using Loctite 243
Removable chassis pieces 40 Nm Install using Loctite 243
Front sprocket 6 Nm Install using Loctite 243
Oil drain screw 15 Nm
Oil strainer cover 10 Nm
Oil filter cover 15 Nm
Cam cover bolts 7 Nm
Spark plug 12 Nm
Rear engine fixing spindle 75 Nm
Centre engine fixing spindle 40 Nm
LH upper engine bolt 30 Nm Install using Loctite 243
RH upper engine bolt 40 Nm Install using Loctite 243

8-8
 8. Technical Data

Item Setting Note

Rear linkage chassis mount 75Nm
Rear linkage swingarm mount 75Nm
Rear linkage lower shock mount 50Nm
8
Rear linkage tri-link mount 75Nm
Upper rear shock bolt 50 Nm
Rear brake lever -
Rear brake master cylinder to frame 15 Nm
Exhaust header pipe 22 Nm Install using Loctite 243
Exhaust silencer link clamp 20 Nm
Exhaust silencer rear mount 12 Nm
Lower triple clamp 20 Nm
Upper triple clamp 18 Nm
Handle bar riser mount -
Upper handle bar clamp 20 Nm
Steering stem bolt -
Steering stem clamp bolt 18 Nm
Clutch lever to handle bar 10 Nm
Front brake lever to handle bar 10 Nm
Throttle twist grip to handle bar 8 Nm
Gear shift lever to spline 11 Nm
Foot peg mount bracket bolts 40 Nm Install using Loctite 243

8-9
 9. Service

9-1
 9. Service

9-3
 9. Service

9-3
 9. Service

9-4
9. Service

9
 9. Service
Confirmation of Maintenance Work
This table is intended as a record of maintenance and repair work including fitting of optional extras and, where appropriate, any recall work.

ITEM ODOMETER READING DATE

9
THIS PAGE INTENTIONALLY LEFT BLANK
 10
CCM GP450 Adventure
Warranty
Information
 Dealer stamp
Owners Data *Important: Please fill in all information*
CCM Warranty Enrolment Form Title: _____________ Initials __________
Vehicle and Owner Data.
Dealer to complete in block capitals and take two copies, Surname: _________________________________
send one copy to CCM Motorcycles Customer Services
(general.admin@ccm-motorcycles.com) and retain one copy
for own records.
Address: _________________________________
Vehicle Data _________________________________
Model: ____________________________________________ _________________________________
Colour: ____________________________________________
County: Post Code:
Vehicle Ident No: State: _____________ Zip: _________

Engine No: - Country: _____________

Registration Number:
Telephone No: ____________
Date of Purchase: Email Address:__________________
I hereby declare that I have read and accept the
warranty terms and conditions contained within this
booklet.
Account No:

Owner signature: _______________________

10-2
OPTIONAL
Why have you chosen this vehicle?
MARKETING INFORMATION a) Tech contents e) Trust in the manufacturer
1. Age: _____________ 2. Sex M F b) Style/Design f) Value for money
3. Occupation
c) Handling comfort g) British built
a) Self-employed e) Student
b) Full-time employee f) Retired
c) Part-time employee g) Unemployed
d) Housewife / husband
4. Buying: Are you ? MESSAGE TO SELLING DEALER
a) A first time buyer
b) Replacing an existing motorcycle or scooter
1 Ensure Warranty Enrolment Form is completed and two
copies taken. Send one to CCM Motorcycles and keep
What is the main use of your vehicle ? one for your records.
a) Commuting c) Business 2 Please write clearly and firmly, recording all data as
b) Leisure requested.
5 What made you aware of this model ?
3 Ensure that the customer understands the warranty
system and requirements and daily safety checks
a) Personal recommendation
before handing over booklet.
b) Seen in a dealers showroom
c) Seen on the road Thank you for your time in
d) CCM web site
e) Other web site (please specify)
completing this form
f) Advertisement in magazine (please specify) The information above may be used to assess and
g) Seen at a show (please specify) improve the CCM product range. This information will
h) Other (please specify) not be passed on to any other agency.
Dealer Pre-Delivery Inspection (P.D.I.)
CAUTION
Failure to complete these checks could result in component damage which would not then be covered under warranty.
Failure to complete these checks could result in injury or loss of life
Although CCM motorcycles are assembled and checked to the highest standard before they leave the factory, it is mandatory that they
receive a full P.D.I. before hand over to the customer.
The following notes should be read in conjunction with the handbook when carrying out the P.D.I. This gives a double check of the motorcycle
and ensures that the customer takes delivery of a safe, quality product.
The Dealer must sign, stamp and return one copy of this P.D.I. form to CCM Motorcycles, along with a copy of the Warranty Enrolment Form.
The motorcycle will carry no warranty until these forms are received at CCM. Note: Transit damage is not subject to manufacturer’s warranty,
and must be notified to the Carrier at the time of machine delivery.
If any defects are found, CCM Motorcycles
must be informed through the standard warranty procedure.
VIN ______________________________________
Engine No. ______________________________________
Ref. No. ______________________________________
Model ______________________________________
BRAKES
Dealer stamp
Check tightness and security of brake hose fittings and look for leaks Signature
when pressure is applied to front brake lever and rear brake pedal. Check for efficient brake operations front and rear
Check fluid level front and rear
FUEL SYSTEM
Check fuel lines for security  No Leaks  Correct throttle action  Idle speed

COOLING SYSTEM
Check fluid level  No Leaks  Coolant 
LIGHTING SYSTEM
Check operation of lights Stop lights Indicators Warning lights Headlights

ALL FASTENINGS, AXLES, STEERING AND SUSPENSION

Check for fastener tightness  Security  Correct action 
CABLES
Check for correct routing  Correct free play  Freedom from snagging 
TYRES
Under normal loading, tyre pressures should be as indicated, for road use with standard tyres:

Dunlop Trailmax - Front - 29 psi

Dunlop Trailmax - Rear - 31 psi 
DRIVE CHAIN
Check for wheel and chain alignment Check adjustment  Check chain is guided correctly onto rear sprocket 
SUSPENSION
Check balance, front and rear, in order that steering is  Check forks for smoothness and material 
not compromised imperfections which may compromise the oil seals
OIL SYSTEM
Check engine oil level  
Date _____________________________ Mechanic Signature ________________________________________________

Mechanic Name (Print) ________________________________________________

10-6
Introduction
CCM Motorcycles thanks you for choosing one of its
Motorcycles.
This booklet contains all the information you need regarding
the CCM Warranty scheme.
To maintain this motorcycle's peak condition, it is
Note:
This Owner's Manual is a valuable document. Please keep
it safe, as it will be required in connection with servicing and
any warranty claim that may arise. The signing of the
warranty enrolment form and change of ownership
document indicates agreement to the terms, conditions and
restrictions herein.

! essential that it is serviced at regular intervals in

accordance with the service schedule.

Please also ensure that you have read this Owners Manual
thoroughly to ensure that you understand completely all the
features of your motorcycle, including the regular safety
checks and other items which should be carried out by the
owner - these checks are vital.
Always take the trouble to secure your motorcycle against
theft.
Use a strong, reliable lock from a reputable manufacturer.
How to Enrol in the Warranty Scheme
Your CCM motorcycle is covered under warranty for a period It is important to keep this booklet, with the counterfoils of
of two years, commencing from the date of purchase. the service records (endorsed by an Authorised CCM
However, your dealer must first enrol your motorcycle in the Dealer), safe. It is your proof that the Warranty cover is
scheme by using the Warranty Registration Form in the front valid.
of this book.
The two-year cover is available at no extra cost, please
check that your dealer has filled in all the details correctly
before adding your signature. The dealer will send the
signed form to CCM Motorcycles customer services at:
CCM Motorcycles
Unit 5, Jubilee Works
Vale Street, Bolton
BL2 6QF
A complete Service History, together with the care that the
motorcycle has received from you, will enhance the value of
the vehicle should you come to sell it.
If you sell your motorcycle, the outstanding balance of the
warranty period can be transferred to the new owner by
using the Change of Ownership / Address Form. The same
conditions and restrictions will continue to apply for the new
owner.

10-8
Warranty Restrictions
1. The warranty may be invalidated if your motorcycle has
been neglected, mistreated or modified in its
construction, function and/or aesthetics.
2. If your motorcycle is used in competitive racing or track
days, the warranty will be invalidated.
3. The warranty will be invalidated if the motorcycle is
repaired, modified or dismantled, even if only partially,
without authorisation from CCM Motorcycles, or other
than by CCM Motorcycles or an official CCM Dealer.
4. If the motorcycle's frame or engine number (stamped
into the metal) has been altered or defaced, the
warranty will be invalidated.
5. The warranty will be invalidated if the power plug has
been installed.
This warranty shall be void if, in CCM's opinion, the
motorcycle has been subject to:-
1. Improper use (this includes racing and motor sport).
2. Improper repair (this includes fitment of non-genuine or
"pattern" parts).
3. Alteration from standard specification in a manner
which affects the performance, durability or safety of
the motorcycle or any of its component parts.
The warranty may not apply if:-
1. The periodic maintenance and servicing are not carried
out at correct intervals.
2. Evidence of this servicing must be produced, if
requested, at the time of any warranty claim.
It is the owner's responsibility to ensure the service
record book is kept up to date by the servicing dealer.
It is advisable to also keep copies of any service or
repair invoices in case the record is lost.
3. Any problem experienced is not notified to a CCM
Dealer within a reasonable time. The owner should
take all possible steps to prevent further damage as
soon as any problem is apparent. Such consequential
damage may not be covered by this warranty.
4. In CCM's opinion, components damaged by the effects
of corrosion were so damaged due to the machine not
being adequately maintained or cleaned on a regular
basis.
5. Reasonable care has not been taken to keep the
machine clean and free from chemical attack by ice
clearing agents, cleaning fluids and other corrosive
elements.

How to keep your Warranty valid
For the warranty to be valid you must:
1. Ensure that the Dealer has completed and stamped the
Warranty Enrolment forwarded a copy to CCM
Motorcycles. This record in this booklet is important
and will need to be produced if you ever need to have
repairs undertaken under warranty.
2. Have your motorcycle serviced by an Authorised CCM
Dealer, or appointed agent, according to the schedule
shown in this booklet.
In fact, having your motorcycle serviced regularly will
also keep it at the peak of its performance, as well as
enabling your Dealer to detect any early signs of faults
and rectify them, before they cause you a problem.
3. Present this booklet to the dealer whenever they
service your motorcycle so that they can stamp the
relevant Service History page.
4. Present this booklet to your Authorised CCM Dealer
when requesting a warranty repair.
5. Observe the restrictions listed in this booklet.
10-10
What to do if you need a Warranty Repair
Should you experience or suspect a problem with your
motorcycle during the warranty period, it must be taken
immediately to ANY Authorised CCM Dealer for the problem
to be investigated. It is important that you describe your
problem thoroughly and in detail.
All claims under Warranty must be submitted on your behalf
through our Authorised Dealers. We regret we are unable to
accept Warranty claims direct from our customers.
Only when you present this warranty booklet will the dealer
be able to advise you whether the repair is available within
the warranty agreement. If it is, they can make
arrangements for the work to be carried out.
Remember, all repairs, inspections and servicing must be
carried out ONLY by an Authorised CCM Dealer or Agent
appointed by CCM Motorcycles.
The warranty does not cover the cost of regular interval
servicing of the motorcycle; therefore all such services must
be paid for.
Note:
The warranty does not cover the cost of
transportation of the motorcycle to or from the dealer,
nor expenses incurred whilst the machine is off the
road for warranty repairs. If you wish to eliminate the
possibility of having to pay for this, your dealer will be
able to advise you of the various breakdown recovery
schemes that are available.
Warranty
What is covered?
Your CCM motorcycle is guaranteed against all defects (of
material, workmanship and design) for a period of 24 months
from the original date of purchase and without any mileage
restriction (unless it is sold as second hand or as an
ex-demonstration model).
Any such defects will be rectified free of charge in terms of
component replacement, provided that the warranty is valid,
particularly in respect of the servicing requirements (see
Warranty Restrictions).
The warranty does not cover machines sold or used for track
days, racing or any other motor sport, on or off road.
Only causes of noise or vibration that are beyond
reasonable limits and which affect the normal riding of the
vehicle are included in this warranty.
What is NOT covered?
The warranty does not include the cost of normal servicing,
nor such items as oil, oil filters, topping up of lubricants,
special fluids and various consumable materials, unless they
are specifically linked to the warranty repair.
The warranty excludes labour.
Defects caused by the use of spare parts or accessories not
produced and/or supplied by CCM Motorcycles are not
covered by this warranty.
The warranty does not cover any spares subject to wear and
tear, such as friction linings (clutch and brake) cables, fuses,
bulbs, spark plugs, tyres, handlebar grips, chain and
sprockets etc.
The warranty does not cover the cost of recovery or
transportation of the motorcycle to or from the authorised
CCM Dealer, nor expenses incurred while the motorcycle is
off the road for warranty repairs, or any other consequential
loss.
Any parts replaced under this warranty become the property
of CCM Motorcycles.
Miscellaneous Complaints should be addressed to your Authorised CCM
Dealer. However, if the problem cannot be resolved with
your dealer, please write to your local agent as detailed or
Statutory rights
post to:
This Warranty is in addition to and neither detracts from, nor
CCM Motorcycles
affects the statutory rights of the consumer.
Unit 5
This Warranty is given on behalf of CCM Motorcycles in Jubilee Works
respect of the CCM product specified on the Warranty Vale Street
Registration Sticker, which was manufactured by CCM Bolton
and/or its subsidiary companies, imported by CCM BL2 6QF
Motorcycles and sold by an Authorised CCM Dealer. UK

Data protection act 1984 (UK)

CCM will use warranty registration information to contact you
directly should the need arise, for example in the event of a
safety recall. CCM may also use warranty registration
information to contact you directly to advise you about new
CCM products or promotions. However, if you prefer not to
receive any communication, please write to CCM
Motorcycles.

Complaints
We sincerely hope you will never have reason to complain,
but we do acknowledge that an occasion may arise where
for one reason or another, you are not fully satisfied.

10-12
Transfer of Warranty
The warranty is transferable at CCM Motorcycles discretion
subject to the Terms and Conditions set out in this booklet.
The same terms and conditions apply to the new owner but
note that the warranty expires in 24 consecutive calendar
months from the date of sale to the original purchaser.
To transfer this warranty, the new owner should complete
the Warranty transfer application on the tear out slip,
ensuring that all the motorcycle details are added and
posted to CCM Motorcycles.
In the event of ownership changes exceeding the number of
transfer slips in this booklet, the new owner should write to
CCM Motorcycles quoting all the details on the warranty
registration sticker in the front of this booklet, including the
date of purchase and current mileage.

PLEASE ENSURE THAT THIS BOOKLET IS PASSED ON

WHEN THE MOTORCYCLE IS SOLD. WITHOUT IT THE
NEW OWNER WILL BE UNABLE TO APPLY FOR A
TRANSFER OF WARRANTY.
Change of Ownership / Address
(Please complete in block capitals)
Vehicle data.
I hereby declare that I accept the Warranty terms, conditions
Model and restrictions contained in this booklet.
Colour
Frame Number
Engine Number Signature
Registration No.
Date of Change
I am the new owner

New owner's data

I have changed address
Title Initial
Surname
Send to: CCM Motorcycles
Address
Jubilee Works
County
Vale Street
Postcode
Bolton
Telephone
BL2 6QF
UK

10-14
THIS PAGE INTENTIONALLY LEFT BLANK
Change of Ownership / Address
(Please complete in block capitals)
Vehicle data.
I hereby declare that I accept the Warranty terms, conditions
Model and restrictions contained in this booklet.
Colour
Frame Number
Engine Number Signature
Registration No.
Date of Change
I am the new owner

New owner's data

I have changed address
Title Initial
Surname
Send to: CCM Motorcycles
Address
Jubilee Works
County
Vale Street
Postcode
Bolton
Telephone
BL2 6QF
UK

10-16
10-2
THIS PAGE INTENTIONALLY LEFT BLANK
Change of Ownership / Address
(Please complete in block capitals)
Vehicle data.
I hereby declare that I accept the Warranty terms, conditions
Model and restrictions contained in this booklet.
Colour
Frame Number
Engine Number Signature
Registration No.
Date of Change
I am the new owner

New owner's data

I have changed address
Title Initial
Surname
Send to: CCM Motorcycles
Address
Jubilee Works
County
Vale Street
Postcode
Bolton
Telephone
BL2 6QF
UK

10-18
THIS PAGE INTENTIONALLY LEFT BLANK
Any statement, description, condition, warranty, representation or otherwise
contained in any catalogue, advertisement, leaflet or other publication shall
not be construed as enlarging, varying, or overriding anything contained
herein.

Nothing in the Warranty shall be construed as an admission of the existence

of any duty or care owed by the Company in respect of CCM Products.

This Warranty shall be construed in accordance with English law and any
questions arising from the Warranty shall be subject to the jurisdiction of the
English Courts.

10-20