TL;DR: Upon further investigation, it just stalls only when in gear, when engine braking, and the problem is accelerated when actually using the brakes or going downhill. Usually stalls out between 0mph and 7mph ish. Whenever throttle is applied it will not stall, and it runs great except for when coming to a stop.
Video of it stalling without even moving: 20220801_201940_1.mp4
Video of it stalling when coming to a stop from 25mph: 20220801_181048_1.mp4
- Stalls with or without KEBC installed. After removing the KEBC it likes to stall out right around the same time the engine braking wants to disengage.
- Stalling occurred with the old and new CVT belt. New belt deflection was measured at 24.5mm w/ 10lbs of applied force on belt.
- I cannot get it to stall for the life of me when the ATV isn't warmed up. Symptoms begin after being completely warmed up.
- Idle RPM in neutral when cold averages 1250RPM (avg.) then when warmed up it drops down to 1180RPM (avg.). Have seen it drop as low as 1080RPM.
- Weird noise comes from CVT when engine braking only (no throttle & no handlebar brakes) specifically around 7mph, almost every time. Attached here is a video of the noise... 20220801_180939_1.mp4 (Noise remained immediately after removing KEBC, although later test drives the sound substantially decreased and at times was non-existent).
- Has new Uni air filter + oiled w/ Uni spray oil. This combined with the removed KEBC has made it a tad harder to stall although it still does.
- Leak Down Test Results: Cylinder 1 (Front) - 2% Leakage & Cylinder 2 (Rear) - 1% Leakage. Is it just me, or is this suspiciously good for 5,000 miles.
- Will not stall in Neutral. Stalls in R, H, L.
- During our most recent winter I installed a brand new OEM Vehicle Down Sensor, which was also the culprit of it stalling out. Symptoms were way different than this though.
- I found this problem when I was traversing very steep rocky mountains up in northern California, and when going downhill it was stalling a lot because I'd be at idle a lot but still need to give it gas on occasion.
- Primary Clutch Cover Bushing I.D. (28.18mm Actual) (28.12mm Max Service Limit)
- Primary Clutch Spring Free Length (77.4mm Actual) (77.0mm Standard)
- Gap between shoe & post (Up to 0.20mm Standard)
- At balancing arrow: 0.46mm
- One space clockwise from balancing arrow: 0.46mm
- Two spaces clockwise from balancing arrow: 0.54mm
- Three spaces clockwise from balancing arrow: 0.58mm
- Stalls in neutral with primary clutch removed.