Have you tried giving him a favourite treat each time you put his harness on? Have you checked he hasn't grown out of it and it's pinching somewhere? Tufnell's first harness lasted two weeks before he'd grown out of it. Have you checked that you're not catching any of his fur in the clips when...
If I'm testing something out like this then every time I change a setting I take a picture of my left hand with one or two or three fingers etc in a pre-determined code so I don't have to try and remember my new setting.
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