I am making some good progress here.
First off, I can say that the system is not at all "tuned" out of the box. Everything is "loose" in order to accommodate a wide range of inputs.
I am going to start a thread - but here is some info.
First measure your exact throttle output. Mine is 0.817V to 3.6V.
Then measure exactly where your controller starts to output - mine is 1.50V
Then measure exactly where your controller switches from PWM to Constant output (you can hear it). Mine is 3.3V
So what we want to do is map the voltage range of 0.817V - 3.6V over to the controller input range of 1.5V to 3.3V
map(throttleMin, throttleMax, controllerMin, controllerMax)
THIS WILL TOTALLY ELIMINATE ALL OF THE SLOP IN YOUR HALL THROTTLE.
I HAVE ZERO SLOP
THE INSTANT I CRACK THE THROTTLE THE MOTOR STARTS TURNING.
I REACH FULL SPEED/CURRENT IN JUST THE VERY LAST FEW DEGREES OF THE THROTTLE.
Now here is how you do it....
I like to set up a motor in a test stand (or turn your bike upside down)
Set the current limit in the CA to 2A (maybe 3 or 4 for yours, my motor is a 12 turn).
Because there is no load on the motor and we want to have some resolution. Freewheel current on my motor is about 1A so this gives me a testing platform to work with.
First: ELIMINATE SLOP AT BOTTOM OF THROTTLE
This is the easiest... first off, if you are not reading the manual
then get the F out of here
I am not looking to spoon feed anyone... just looking to help those who are trying to help themselves
8.18 AUX Threshold
This is what sets the "turn on" threshold for your throttle. You want to set this just a tiny bit over what your throttle sits at. Mine sits at 0.817V so I set this threshold at 0.820V. Setting it below 0.817 (for mine) results in the motor turning with no throttle. Setting it any higher than it needs to be results in slop at the bottom of your throttle
Now we are mapped -> 3.0V range starting at 0.820V and ending at 3.820V. (range is 3.0V no matter what... cant change that)
That is the first part of our mapping.
Now all we have to do is set the output range.
My controller responds to 1.5V to 3.3V
iTermMin = 1.49V
iTermMax = 3.3V
This means that when my throttle first cracks (0.820V) the CA will begin by putting out 1.49V
Now we have mapped 0.820V of input to 1.49V of output.
iTermMax is the highest value the CA will put out, so setting it at 3.3V eliminates the slop at the top of your throttle.
Ah.... ain't that better?
Now there are only 2 more things we care about. I will tune the feedback gain under load as this is totally system dependent.
As a side note....
For those that do not want current throttle but do want full range on their hall throttle you can do this exact same procedure but set it up for Speed instead of Current.