Are you able to position your front wheel so accurately at the frame centerline that your brake disc is not central in the caliper slot? If the answer is yes, then maybe your rim isn't spoked to the correct offset?I seem to have a non-standard rotor. It is about 0.058" deeper from mounting surface to outside contact area surface than other Commando rotors I have measured. This leaves the rotor contacting the outside pad and very little slider clearance (0.015").
If all of this has been verified, you could have your brake disc ground or milled.
- Knut