The reason why the 2nd gear dove tails wear out is because of the shifting canister design defect. The shifting canister groove for 2nd gear fork doesn't push the 2nd gear dove tail far enough inside the female part of the other gear, so its always at the edge, and slips and wears out over time. I think that what you did by welding the dove tails is a good idea, especially if you make them a little longer so that they can fully engage more.

Great work, thinking about a V Max but this issue really puts me off, had the same issue with an 87 Kawasaki VN15, hadn't passed my test when i bought (here in the UK) it so didn't test ride it, on first ride it was popping out of second, couldn't face the job, complete strip down but also engine strip down (barrels and pistons need to come out) too so an engine rebuild, sold the bike spares or repairs and lost about £1000

same issue as fjr1300

Where are you located?

The 85 n some 86 had that 2nd gear problem there was a recall to update that gear I remembered. I was lucky my 86 did not have that problem. They also detuned all the Vmax HP down from 140 to 130

It's been awhile since, did it hold.

What does dovetailing it mean...??

that friggin music has got to go man