Our R1 started popping out of 2nd gear last night. Is this a problem anyone else has had? What was the fix. Hoping to work around it temporarily by gearing it for third.

shift lever too loose/flopping handle is heavy w/clutch attached, tightened bolt more, or arm/hand hit shift lever

Had the same issue and a heavy handle was the culprit. I attached rubber straps to both sides so it held the handle tight and eliminated the bouncing and firmed up the shifting as well.

Tom

The real problem is your "Dogs" are just plum worn out.

Honest Dad himself

I'm fairly certain it is the dogs, not to discount some of the other ideas but it is the same shifter/clutch setup we've run for the last two years. I'm going to try to regear it to run third and see if we can work around it for a couple of weeks. This is kind of a busy stretch. I'll probably be on the lookout for a transmission and just replace it when I get a chance.

Can you not have the gears recut, for racing, I see where most of the big shops provide this service, they cut the dogs at an angle, which makes them pull themselves together, to keep them locked. Just a thought! Bob

The newer bikes come with undercut dogs right from the factory. The cost and time needed to send them off to be ground is kinda of prohibitive, making a gamble of used parts the better choice. This motor was probably owned by a serious racer who spent a lot of time at the drag strip.

I have used rubber straps before and they will work in a pinch.

Honest Dad himself