I have the same problem. It's in the design of the Perch; the tip where the clutch pin touches is just a few mm too short. FP is aware of it and is working on a new perch. Contact them and I'm sure they will send you one as they want a good name in the industry. I have both a set of Pazzo's and FP's and the Pazzo's don't have same problem. You can even put them side by side and see the difference.
Here is some email traffic from FP racing that will explain and contact info:
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Keith,
We spent the day dealership hopping….
We had some interesting results.
I wanted to be sure that the part I was sending you was correct.
We verified the dimensions to the Solid model and we do have the correct parts in stock.
Here is where it gets interesting.
We test fitted 21 motorcycles.
Mostly 03-09 Hayabusas with some GSXR1000 05-08 models mixed in.
Of the 21 bikes our part worked on 16 of these bikes. The really interesting part is that on more than one occasion the part worked on one model and year but not on the same model and year at a different dealership. This is obviously casting tolerances. We need to make our part so that it accounts for all of these variations.
Because it is not a safety issue we will continue to sell the remaining stock we have on hand. However the engineering group is working on a new CAM output for the machine to correct all future runs of the C01 so that it will engage the clutch switch in position 1.
Since this part won’t have any better results on your bike than the one you have I will not send this one out. What I will do is send you one of the new C01 perch blocks once they have been manufactured.
Unfortunately I don’t know when that will be just yet. The Cam will be finished tomorrow and placed in the Que for fabrication. I will contact you when they are ready to ship.
As for the parts you have rest assured this is not a safety issue and will not affect the performance of the clutch itself. The simple work around is to start the bike in positions 2-6.
Mike
FP Racing, Inc
Engineering Group
1-877-FP-LEVER ext 4
FP Racing Tactical Bi-Folding Levers