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I'm about to buy a 2003 400ex that has a noise in second gear and I'm wondering how hard it is to replace second gear, do you have to split the case halves, or not, are the gears just inside one of the covers on the side of the motor?
 

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Requires complete engine disassembly and many of the transmission parts are no longer available - typically the gear on the input shaft goes bad due to the use of improper oil and it is NLA - the gear it mates with on the output shaft is available, but the engagement dog on the output shaft that engages to make second gear work is NLA.

Pre 2005 are just parts vehicles
 
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