Just solved this one before I got your reply.
The wire was routed through network, not simple route. (per #1 and #6 above) After a deeper inspection, the first network segment was found to be .00005" off of the starting CSYS. I replaced the first vertex on the network segment with the origin point of the starting CSYS.
Is there a way to set a different threshold? That minute number should not be cause for failure - at least not in our simple routings.
Thank you.