BoonDocker 700-800 Turbo User Manual

M7 / M8 Arctic Cat Turbo (Pump Gas)

EFI Control Box Instructions

Before you begin, please read all the instructions below and check kit contents.

Kit Contents:

Quality check by:
___1 Control Box
___1 EFI harness
___2 black connectors
___1 battery/jumper connector
___1 Reusable Zip Tie

Arctic Cat Wiring Harness Connector Assembly Instructions

The two black connectors must be installed on the Control Box EFI harness as shown below
before continuing with the installation.

All Models: Connect a test light to the chassis ground. Unplug a stock injector. Connect the other connector of the

test light to one of the contacts on the stock injector connector. Pull the starter rope and watch for the test light to
come on. If there is no light, try the other contact terminal. The terminal that produces light is positive.
After you have determined which of the terminals is positive, insert the red wire of the BoonDocker harness into the
black connector to correspond with the positive wire on the factory connector.

Insert the terminals into the connectors by following the steps below:

1. Non-1000 connector: Hold the black connector

with its locking tab up. Insert the terminal with its
alignment tabs up (see picture).

Note: Do not reference the wire positions to the yellow
dot side of the connector. Refer to the opening
paragraph for connector assembly.

Look inside black connector to verify that the lock tab
inside will mate with the slot in the terminal (below
guide tabs).

2. Push the terminal into the black connector. The

terminal will go part way into the connector and stop.

1000 connector: Orient the black connector and pin
terminal as shown in picture.

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – [phone]

website: www.boondockers.com - email: [e-mail]

Revised 12-01-00 Page 1 of 15

3. Using needle-nose pliers, pull the terminal the rest

of the way into the connector. You should feel the
terminal lock into place (you will feel a slight

“pop”). The rubber seal should be flush with the

end of the connector. Use care to not gouge the
terminals.

4. If a terminal must be removed, use pliers to carefully

push the terminal out of the connector. The terminal
can usually be re-inserted one more time. Don’t do this
unless absolutely necessary! The terminal tabs need to
be pried up slightly before re-inserting. See photo of
terminal at right for tab location. Use a 1.2mm or

0.050” jeweler’s screwdriver to pry with. Check to be

sure that the wire can resist a slight tug without coming
out.

I. Theory of Operation:

The Boondocker Control Box connects between the sled’s ECU (Electronic Control Unit) and the fuel injectors. It does

not reprogram or communicate with the ECU. It only modifies the existing signals sent from the ECU to the fuel injectors.
By modifying only these signals, it is possible to make fuel changes while keeping the stock fuel map. This means the
ECU can still compensate for engine speed, throttle position, barometric pressure, engine temperature, air temperature, etc.

The Control Box can reduce fuel or increase fuel amounts for certain rpm ranges and load conditions. This is done by
changing its fuel adjustment settings by using the buttons and LCD display. As with tuning a carburetor, it is possible to
go too rich or too lean!

Note: Be sure you know how to properly tune an engine before you adjust the fuel settings! Use of EGTs and plug and
piston readings are highly recommended when tuning.

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – [phone]

website: www.boondockers.com - email: [e-mail]

Revised 12-01-00 Page 2 of 15

IMPORTANT NOTES – READ THIS!

Note 1: We recommend using Dielectric Grease on all connections to help prevent corrosion on the terminals.

Note 2: Avoid exposing the Control Box to environments where static charges may exist. For example, quickly

removing a sled cover from the sled in a dry environment can create a static spark that will damage the box (especially if
box is mounted on handlebars).

Note 3: The Control Box is sealed – do not take it apart or it will no longer be sealed. The Control Box is designed to be

splash-proof. Do not submerge or subject the box to high-pressure spray. During long periods of non-use it is
recommended that you do not leave the control box exposed to the elements.

Note 4: If the headlights have been removed (hood is removed or aftermarket hood is used), the electrical system can

cause interference with the Control Box. In some cases, the sled’s computer may become damaged! We recommend
and sell a 100W power resistor that can be used to place a sufficient load on the electrical system to avoid this condition.

Note 5: Always use Resistor Spark Plugs! Non-resistor plugs will cause electrical interference with the Control Box.

II. Control Box Harness Connectors

The Control Box will plug directly into the factory injector connectors. There is also an unused connector for the optional
Nitrous wiring harness or for the battery jumper (see below).

Note: We recommend using Dielectric Grease on all connections to help prevent corrosion on the terminals.

III. Battery / Jumper Connector

The supplied Battery/Jumper Connector has a dual purpose. It
can function as a battery connector in order to supply voltage to
the Control Box when the engine is not running, and it can
function as a jumper in order to bypass the Control Box.

1. Battery Connector

The Control Box is designed to operate without a battery – the
box will turn itself on whenever power is applied for the fuel
injectors. However, a 9-volt battery (not included) can be
plugged into the box through the Control Box’s connectors with
the supplied battery / jumper connector in order to operate the
box without the sled running. This battery connector plugs into

the Control Box’s nitrous connector (refer to picture below).

Secure the battery to the connector with a zip tie in order to
provide a strain relief for the 9-volt connector. The battery can
also be secured to part of the harness if it is to be used on the sled while it is running.

The battery connector can be left plugged in during engine operation, but the nitrous harness (if used) cannot be plugged
into the Control Box. The battery will eventually drain if left connected to the box, so it is best to disconnect the battery
when not in use.

2. Jumper Connector

The Battery/Jumper connector can also be used to bypass the Control Box in case the sled needs to be run without the
Control Box. Disconnect the Control Box from the EFI harness and plug in the Jumper connector - the injectors are now
connected directly to the sled’s ECU.

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – [phone]

website: www.boondockers.com - email: [e-mail]

Revised 12-01-00 Page 3 of 15

IV. Box Mounting Locations

The best mounting location is on the dash or on the handlebars (if
pad is removed) using the supplied Velcro strips. Before applying
the adhesive strips, thoroughly clean each surface (rubbing alcohol
works well). It is also best if each surface is room temperature.

Mounting the box under the hood is less desirable (LCD is more
likely to have condensation), but if it is necessary, keep the box
away from excess heat (like the exhaust), away from any moving
parts, and away from the ignition coil.

Note: The location on the plate in front of the steering shaft, above
the exhaust pipe gets very hot! We DO NOT recommend this
location.

V. EFI Wiring Harness

The EFI harness plugs into the stock sled’s injector connectors as follows:

1. Disconnect the stock harness connector from each fuel injector. Note which connector goes to which injector.

2. Determine where the control box will be mounted and how the harness will be routed. Route the harness so the

injector connectors end up near the sled’s fuel injectors.
Note: If the control box is to be mounted on the handlebars, it is best to have the harness follow the routing of the fuel
line to the fuel rail (inside of the oil bottle) instead of following the sled’s harness around the outside of the oil bottle.

3. There is a left (PTO) and right (MAG) pair of

connectors for each injector (see picture). The
shorter length connectors go to the MAG side, and
the longer length connectors go the PTO side.

4. Plug the gray Control Box connector (female) to the

sled’s fuel injector, and the black connector to the

sled’s gray injector connector. Do this for both the

MAG and PTO sides.

Note: Be sure the black harness connectors latch

securely to the gray injector connectors. This may require pushing the latch on the gray connector down over the tab
on the black connector.

5. Connect the Control Box harness ground wire to chassis ground, not the engine ground! A good ground connection

is extremely important!

6. Use zip ties to keep the harness away from moving parts. Use reflective heat tape if the harness must be routed near

hot items such as the exhaust Note: heat-tape may be used to protect the harness and connectors near the fuel

rail from the hot exhaust pipe.

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – [phone]

website: www.boondockers.com - email: [e-mail]

Revised 12-01-00 Page 4 of 15

VII. Control Box Menus

A. Intro Screen

When the box is first turned on (by the engine or battery), the Intro screen is displayed. Press any key to go to the main
menu. An example Intro screen display is shown below:

AC Turbo 700/800

vers:5A22xxx

In the example shown above, this screen displays the following information:

AC Turbo Sled model This box is designed for an Arctic Cat. Boxes for other sleds will have other

lettering. Note: Be sure the Control Box is for your model of sled!

4A5dBDT Sofware Version This is the software version of the box. The box can be reprogrammed only by

sending the box back to Boondocker.

B. Main Menu

The Main Menu is shown below:

Main Fuel Stats
Menu ExV Map1U

The current selection is shown by the Right-Arrow and the cursor (underscore below the “F”). Use the arrow keys to
move the cursor. Move the cursor to the desired selection and press the “SEL” key to select the desired menu option from

one of the following:

Fuel Go to the Fuel adjust menus (see Section 1).
Stats Display runtime data, captured data, and recorded maximum data (see Section 3).
ExV Menus for Exhaust Valve and Button setup (see Chapters VII and IX..).
Map Go to the Map menu (see Section 2)

The current Map number is displayed as “Map1U”. This indicates that map number 1 is being used and it is Unlocked.

1. Fuel Adjust Menus

This selection is used to make fuel adjustments. There are five Fuel adjust screens (examples shown below). There are
two screens for adjusting fuel according to Boost pressure. There is one screen for adjusting Accelerator pump fuel.

The first fuel screen comes up after selecting Fuel and pressing a button. Go to the next fuel screen by pressing the “SEL”

button. After pressing the “SEL” on the last Fuel adjust screen, you will return to the Main Menu. Use the Left/Right
Arrow keys to switch between settings. Use the Up/Down Arrow keys to change the settings (if the current map is

unlocked). Sample Fuel adjust screens are shown below (actual rpm settings and number of screens may be different for
your model).

Fuel screen1: M1L LO MD HI tr

3000 00 00 00 00

Fuel screen2: M1L LO MD HI tr

5000 00 00 00 00

Note: for more information on additional fuel or boost
screens refer to advanced mode instructions.

Boost screen1: M1L Lo Md Hi

PSI 00 00 00

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – [phone]

website: www.boondockers.com - email: [e-mail]

Revised 12-01-00 Page 5 of 15