There appears to be a learning from experience problem here
Currently there is the exact same thread over at the Tiger1050 forum about a Pazzo lever not working properly for clutch engagement..The owner over there can't use a setting lower than #5 for starter engagement...I have put Pazzos on both my Rocket III and 07 Tiger and I am able to use setting #3 on my Tiger....I found a similar situation to this problem after installing the Pazzo on my Rocket brake side...The lever wasn't engaging the brake actuator piston...couldn't figure it out so I took the Pazzo off and compared it to the stock lever..The end of the Pazzo than engages the brake piston was shaped a little different than stock allowing much less contact...it doesn't take much of a difference I found between working and not working...I ended up fashioning a shim that I put in between the Pazzo and the brake piston and it has worked fine for the past year....Sounds a bit crude but of course it can't be seen...Make sure you have the 2-3mm of clutch freeplay to give yourself the maximum contact with the starter lockout button..Also if you take the Pazzo lever out compare it to your stock one and see if the Pazzo engagement end is shaped a little different.. Hope this gives you some understanding as it can be frustrating ....
