I previously posted this question as a reply to an earlier thread that seemed to be on-topic, but got no replies and am now unable to locate the older thread, so here goes:
I have a 2007 CVO Ultra Classic. It has the 110 motor with the 6-speed. It has a persistent and chronic stalling problem whenever it's been run long enough to be fully warmed up (say up to an hour without stopping). It'll be running great as it always seems to, then I'll come up to a stop sign or traffic light and as soon as it drops to idle, it stalls (not every time, but sooner or later almost every time I go for a ride). Start it back up, it'll idle fine and run fine until the next stop sign, and then stall again as soon as it drops to idle again (again, not every time). Sometimes instead of stalling it'll drop to a very low idle and chug-chug-chug like it wants to stall, and a blip of the throttle will bring it back up to normal (until the next stop sign). I bought the bike from the second owner, who claims he did nothing to it but ride it. The bike is mostly stock, the only mechanical changes being 4" pullback bars and Rinehart True Dual pipes. It runs like a raped ape generally, so I'm presuming a download was done when the pipes were installed, but I have no way to know for sure. When I realized the stalling problem wasn't going away, I took it to the dealership where it was originally purchased. They kept it for a week but claimed they could not reproduce the problem, diagnosed it as a defective voltage regulator and billed me $400 to replace it. And of course it made not the slightest difference. They also claimed it does not "throw a code" so I'm trying to figure out what kind of problem would be so consistent but not throw a code? I took to a different dealership, who kept it for a week and returned it to me without even addressing the problem. The first independent shop I took it to did the same. I took it to a second independent mechanic, who finally took me seriously and started to work the issue. He did a lot of testing, and found and fixed numerous air and vacuum leaks, replacing several gaskets and o-rings in the process. He pronounced the bike leak-free. It still stalls. Next time in he replaced the spark plugs and plug wires, and the fuel injectors and IAC. It still stalls. I took a celphone video of the bike stalling over and over, on a day I got back from a ride and it stalled in my garage when I pulled in. The video will show it stalled, I restarted it, it stalled again, and it repeated this over a dozen times as I restarted it over and over. Finally, I restarted it for the umpteenth time and suddenly it ran and idled fine. But I have no way to understand why, either why it stalls or why it sometimes doesn't.
Has anyone ever seen this on any other bike with this motor? 2007 was the first year of the 110 motor with 6-speed trans. Could this be a "first-year-teething" problem? It's very frustrating as you can imagine. On solo rides not so much, but when riding with any other bikes I find myself feathering the throttle whenever stopped, to avoid it possibly stalling and the subsequent embarrassment of it. I shouldn't have to do that! What can I do? Can anyone think of a possible solution I haven't already tried? Thanks!