You'll need the DTRE/TZR Crank cases, TZR/DTRE Crank, fly wheel stator CDI, pick up and loom.

Basically, you need a DTRE/TZR Engine.

No sealant, just make sure the mating faces are completely flat.

https://dt125r.co.uk/topic/11/how-to-i-gentle-skim-your-head-barrel

@Sgt-Robuck-5 Sounds like a bigger problem to me. I highly recommend Athena and of course genuine.

If the surfaces aren't flat then no gasket will seal. I always recommend a quick homemade skim on the head and cylinder before refitting.

@oldman lovely!

Yeah not sure why, ive seen 2nd hand cases labelled 3BN 00, 01 and 02. Maybe its the place of manufacture, or just subtle changes in materials or something? Ive noticed the 00 case has a couple of shallower indents on the outside of the case, and a couple of radius corners are subtly different. Could be a different manufacturer

I think it's one of each bud. Think. To be fair once you split the engine it should be obvious. They will be labelled appropriately.

@Calum COOL vid thanks bro!!! :raising_hands_medium-light_skin_tone:

@finnerz89 Used to notice it a lot on my little 50cc Aprilia RS when I was kid coming home from a late night!

@Bluestoesonnose I would look in the Haynes manual for answers on this???

here's another simple spark plug guide;

https://www.briskusa.com/spark_plug_cross_reference_heat_range_chart

@2stroketerry Yeah that's more like it!

You'll want a fly wheel puller. And you'll need to lock the crankshaft off to remove it.

Pretty simple job though.

https://www.ebay.co.uk/itm/PRO-13PC-HARMONIC-BALANCE-CRANKSHAFT-GEAR-PULLEY-PULLER-FLYWHEEL-BALANCER/122134506298?_trkparms=aid%3D555017%26algo%3DPL.CASSINI%26ao%3D1%26asc%3D53530%26meid%3D7ad1578465b741d992b0a55ca04a7f02%26pid%3D100505%26rk%3D1%26rkt%3D1%26%26itm%3D122134506298&_trksid=p2045573.c100505.m3226

That for a DTRE, you'll need a different one for a DTR.

@Calum ok mate will do thanks 👍

https://imgur.com/a/dvpHDWy

Went to a place where they teach welding and stuff today. A guy there made a pretty good job.
Not knowing exactly what material it was combined with a dirty oily piece and I'm definitely happy.

I'll trim down the piece a sticking up on the first image.

Correct me if I'm wrong, does the starter wheel(the wheel that's connected to the flywheel) spin with the engine? Or does it only move when the starter is turned over?

In that case, the tolerances shouldn't matter as much.

There is a guy on ebay selling complete kits for 100 quid bought one a few weeks ago but he has more on there

@Bananper The dog ears are in the gearbox, they are what shift the gear cogs into place from the selector drum.

I can't see why there would play. The primary shaft is fastened against the case and the bewring.

Skim the head and barrel before you leave, it's the one thing that WILL let you down on a DTR, even if it's not visibly warped it will leak from the gasket, the surfaces need to be absolutely perfect.

@jimmydc98 If you had a chuck big enough you could machine it in a lathe.

But it does sound like you would need to send it away.

To be honest with you, it's really not that expensive. It cost me £80 to get my Starlet head chemically cleaned and skimmed.