Glad you mentioned that Mitzzy, after a bit of research, I suspect the problem was likely started those 1 or 2 times when I didn't firmly kick the lever into second and it popped out when the bike was brand new. From there I suspect it started an accelerated wear scenario leading to where it is now, completely rounded 2nd gear dogs/output gear.
Have a request in to see how much under cutting the 2nd gear dogs and output gear will cost. If it's not terrible, I'll order new gear/dogs, have them undercut, and have them installed when they do the warranty repairs.
All this ****, literally 2 days before I am paying for my big power upgrade.... so gutting to realize now some asshat Harley mechanic impersonating a Triumph tech is going to totally disassemble my bike because I don't have a garrage. I just know it's going to come back changed and something isn't going to be the same,