Maybe a small question to make understand the boot up... kszaq
If I get it correct, boot process is handled by u-boot, which exist in different versions. So powering up the boxes, u-boot normally just boots into nand, where Android is installed and starts the Android kernel. With using the toothpick method, u-boot gets patched to support booting from SD or USB, too. So when powering up after patching u-boot, it looks if SD is present with bootable kernel and starts it if it is. If no SD with valid system is found, it tries USB. If no bootable system is found on USB or no USB is present, u-boot simply boots NAND, correct?
So it works like a normal PC's BIOS does after being patched. It simply looks for a bootable system in the order SD, USB, NAND? So resetting all u-boot variables just makes it boot from NAND, so it's faster, as it doesn't have to 'wait' for SD or USB.
If I'm getting it right, kernel only comes to matter, after u-boot has done its job, correct? So boot failures can't really be a matter of kernel?
May I ask some questions?
It's only S905 devices that suffer the boot failure? S905x devices aren't hit?
Is there a LE version thats reliable booting S905 devices? What's the changelog between this reliable version and 011?
Is there a way to get u-boot version from a running system?
Does it matter if it's 64 or 32 bit?
Do the ones suffering the boot hang have LE installed to NAND or are all using SD card? When using SD, what's installed on NAND? Android or LE?
For me it seems a 'structured' bug hunting would be more effective. So we should find a version that's working reliable in regards to booting and go from there. The above questions show that we have a very huge variety of possible influences (u-boot version multiplied by what's on NAND multiplied by 32 or 64 bit multiplied by using SD or USB multiplied by reboot or cold boot multiplied by using external USB devices or not...)
So my suggestion would be to go back to a reliable working version. Doing this should include a reliable test setting (64bit from SD card with no external devices connected to USB doing only cold boots is what I would suggest to minimize error prone variables)
For all other errors (audio delay, PVR problems, stuttering, etc) I would suggest using the test files from:
Samples - Official Kodi Wiki
so all have the same base of files
Jm2c