Have you seen the extended shift lever from Happy Trails? I just installed one on my'22 so I can use my heavy cold weather boots. Plenty of room now and the 1" longer lever makes all shifting smoother. $58 shipped...well worth it IMO.Well I was able to take a closer look at the shift lever, and sure enough the little bugger had moved a tooth or two upward. It was enough movement to cause it to hit on the sprocket cover, but only when shifting from 1 to 2, other gears cleared just fine. I moved it back to stock position using the dot on the case as reference and it is able to shift into 2nd. It didn't appear to be a clearance issue at first as it had clearance from the case, where it was hitting the sprocket cover was further in after the first bend in the lever. I'm surprised that it was able to move like that in just a months worth of daily use.
I don't think I have owned a bike with less clearance for adjusting the shift lever than this one, there is almost no ability to reposition the shift lever, and my boot simply doesn't fit under the stock one. Even with the extended lever I am still mostly shifting with the side of my toe. Weird design.
Anyway thanks for the responses, it helped me not get to far ahead of myself.
Happy Trails Heavy Duty Shifter Kawasaki KLR650 All Years 1987-2022