@Daz:
Pretty much Zoros entire pre-skip fight resume has involved himbeing handicapped in some way, or overcoming a hurdle specific to his fighting style.
Against Cabaji and Hachan, as you say, Zoro is severely wounded prior to battle.
At whiskey peak, every single one of his opponent is a chump he could handle easily, but by throwing 100+ of them at him at once he has to break a sweat and take a hit.
At Alabasta, his opponent is completely immune to Zoros fighting style, so Zoro needs to break new ground to win.
Both Braham and Ohm were long-ranged fighters, putting short-range Zoro through a lot of hassle until he busted out long range moves of his own.
Vs both the Nyanban brothers, Hatchan, and Ryuma Zoro was fighting with less than three swords; and yes, Zoro has a few one sword-finishers, but its always been clear that his overall fighting ability is reduced when using less than three swords. In his fights against the Nyanban bros and Hachi, getting three swords was what allowed him to win at all.Kaku is an anomaly in the sense that he was just really tough and skilled, enough to give the fight some satisfying back and forths. Even without giving Zoro some handicaps, Pica could easily get by on just being really tough.
As for the other straw hats, sure they got their own fair share of handicaps. Sanji fights a fishman karate-expert underwater, Nami fights without full knowledge of the clima tact, Franky fights while low on fuel, then once powered up his inferior but flying enemy shifts the fight to a waterfall, Chopper fights with increasingly unpredictable and unreliable transformations as he's used too many rumble balls, Luffy fights a poison man he can't touch etc.
But those handicaps made the fights great, fun, dramatic and memorable! Its time to throw some gravel in Zoros machinery Oda, we had the Welcome Back power demonstration party at Fishman Island!
Zoro fought the Meowban Brothers, Whiskey Peak bounty hunters, Mr. 1, Braham, Ohm, and Kaku at full power. He just struggled against them. Getting his swords stolen, being unable to hurt your foe due to lack of skill, lacking ways to fight long range opponents… those are not handicaps, they're Zoro needing to improve.