Any joy finding out what your problem is. Im just waiting on a gasket set for my Scorpa 295 then will start rebuilding. Ive ordered new gears as me dad said they were worn but someone else told me that they are ok and eouldnt be causing the problem. Howeever the gear shaft is bent on the outside of the crackcase but spins freely and is straight on the inside of the crank plus the pawl assembly (linked to end of shaft inside crank) spins at 90 degrees to the centre of the crankcase if you know what i mean. I think this may not be turning evenly which may be the reason why my bike was jumping out a gear when put under load. Have you checked the shifter drum where the channels are for the two selector forks, or the index shim. Was the return spring for the gear lever intact and working. This may be no help at all to you but i dont know too much, just what ive been learning scanning the net trying to sort mine out. Lastly the teeth ends on your 2nd gear on the lay/clutch shaft well small as mines not as squared off as the rest of the gears and 1st gear which is attached to the shaft the teeth look a bit pointed but someone from SWM told me that they are like that when noew but are case hardened...not worn.