ATV is a 400L 2wd

My chain broke and made it's way into the transmission.
We will attempt repair of the case with the hole in it.
Any tips on disassembly of the transmission?

Also right now the input shaft turns freely and I can see 2 gears moving, courtesy of the hole the chain made. The output shaft is stuck, does NOT move at all.

 

Several videos on youtube that can help including this one from a couple guys that never worked on one before looks like.https://www.youtube.com/watch?v=VNoMllN95xU The manual is still the best as it shows step by step pics on repairing the gear case.https://www.tradebit.com/filedetail....5-full-service

 

Thanks OPT. good info
I have started the cleaning process. I have the manual and now watching the video i see what we will be getting into. Should be fun.

 

Hardest part is to get the shift shafts back in the case slots because of the spring loaded keepers.Usually a small screw driver or pick can help slide them back.

 

I am not sure how fixable this is but we will try.

 

Nasty.. Broken case part is probably what's locking things up also.I'd be checking ebay for a good case half if you can't do anything with this one.

 

Here is our repair
After the brazing JB weld was added to make sure it does not leak.
Still need to put it back together.

 

Not bad..I've seen ugly repairs a lot,but this looks pretty good.

 

I did take several times to get onto this brazing, if that is the right word. More practice and it would have been better.

The few times we drove the machine, in between the motor rebuild and the tranny damage. It was dificult - grinding to get into gear.
Is there anything we should look at while the tranny is opened?

 

Sliding dog gears and engagement gears. Make sure the lugs engage the gears properly,not rounded and worn plus make sure the shift forks are ok,no deep grooving.Always replace the silent chain and seals if you crack open a gear case.