My 2000 starting popping out in 2nd around 13,000 miles. I tried to ignore it... but it just kept getting worse. I ended up tearing down the engine and having all the gears undercut by R&D Motorsports in Clearwater, FL. The bike shifts amazing and it not hard to get into any gears... always quick, smooth, and solid! You'll never miss a gear again!
Granted... this is the most expensive option, but it?s also the best IMO! New bikes these days all come with a small degree of undercutting, but it?s nothing compared to the amount that R&D will do. All professional road racing and drag bikes have this process done. It ensures positive gear engagement every time!
In 2007, the undercutting cost me right around $750, plus all the gaskets and whatnot that you need to rebuild the engine. I ended up sending my head out for overhaul, added exhaust, jet kit, clutch conversion, & AIS block-off at the same time... So, I was upward $2200 when it was all said and done! But hey... you got to pay to play!
Call R&D Motorsports and talk to Mark. He is very very knowledgeable on these R1 trannys and will take the time to explain the process to you!
Do a search; there are hundreds of threads on the 2nd gear pop out issue.
But, if you keep pushing like it is and you'll eventually lose the whole gear? or worse!
If its got tits or tires, your going to have problems!