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Ironhead Transmission Woes

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I have a 1980 Ironhead, with a 4-5/8 stroker.

My problem is 2nd gear.

Last summer I went through the transmission, the dogs on 2nd gear were worn some, so I bought a 2nd gear, which wasn't a Andrews.

I set all the clearances per the manual.

Under acceleration in 2nd gear, when I hit 6000 rpm, the transmission would pop from 2nd to 1st, and put your nose over the handlebar. So, I tore the transmission apart and reduced the dog clearance to 0.010. Now the trans would develop a clicking noise because of the reduced dog clearance.

So, I tore apart the trans again, and was able to set all the dog clearances to the minimum clearances prescribed in the manual. Guess what, pops out of
2nd again.

Maybe I should of bought the Andrews gear.

Any thoughts ?????

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