BoonDocker Apex Turbo User Manual

Yamaha Apex Boost Capable

EFI Control Box Instructions

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

Control Box Kit Contents:

Quality check by:

___1 Control Box

___1 EFI harness

___1 Pressure Transducer

___1 pressure transducer harness

___1 mounting bracket for transducer

___1 battery/jumper connector

___2 velcro strips

IMPORTANT - PRODUCT REGISTRATION: Please register this product online as soon as possible (if you do not have internet access, please call us at 208-542-4411). It is required that you register this product so you can receive technical support, warranty claims, and so you can keep informed of product updates.

To register, go to www.boondockers.com, select “SUPPORT” then select “PRODUCT REGISTRATION”. Please complete the on-line form.

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 an Air/Fuel Guage and plug readings are highly recommended when tuning.

IMPORTANT NOTES – READ THIS!

Note1: Never unplug the Control Box when the engine is still running! Electrical damage may result which is not covered under warranty!

Note 2: We recommend using Dielectric Grease on all connections to help prevent corrosion on the terminals.

Note 3: 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 the box is mounted up on the handlebars).

Note 4: 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 5: Always use Resistor Spark Plugs! Non-resistor plugs WILL cause electrical interference with the Control Box.

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805

www.boondockers.com –	email: [e-mail] – fax: [phone]
Revised 05-07-07	Page 1 of 16

II. Wiring:

A. Injector wiring:

The Control Box EFI wiring harness plugs in between the stock injector connector and the injector itself. Starting with the shortest pair of connectors (yellow and tan wires), plug these into the injector for cylilnder #1 (PTO side). Continue with the next longer pair etc so the longest set of wires are connected to the injector for cylinder #4 (MAG side).

The white connector connects to the Control Box.

B. Jumper/Battery Connector

The jumper can be used in one of the following two ways:

1.A 9-volt battery can be plugged into the jumper and the jumper can be plugged into the female connector (pressure transducer connector must be unplugged) to power the Control Box. This allows the Control Box to be turned on when the engine is off.

2.If the Control Box is unplugged from the injector harness, the jumper can be plugged in its place into the injector harness (9-volt battery is not required). This bypasses the Control Box to allow

the sled’s ECU to directly drive the injectors. This is for emergency or diagnostic use only!

III.Control Box Mounting

Location

The best location for the Control Box is on the panel below the handlebars (see picture). The box can also be mounted under the hood, on the dash, or on the handlebars 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.

If the box is mounted under the hood, keep the box away from excess heat, and away from the ignition coils.

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805

www.boondockers.com –	email: [e-mail] – fax: [phone]
Revised 05-07-07	Page 2 of 16

IV. Control Box Operation

The control box is powered only when the injectors are on which occurs for a few seconds when the key is first turned on or when the engine is running. Up to 5 different fuel adjustment maps are stored in the box (currently all with zero values). The box will remember what map was last selected and what its settings are – you do not need to do anything to save a map when making adjustment (see Fuel Adjustments below).

A. Intro / Startup 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:

Apex Turbo 1000

5B5jBD N2O:FIX

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

Apex Turbo	Sled model. This box is designed for the Yamaha Apex. Boxes for other sleds will
	have other lettering.
5B5jBD	This is the software version of the box. The box can be reprogrammed only by sending
	the box back to Boondocker
N2O:	Shows that this Control Box is nitrous capable.
FIX	Nitrous pressure regulator type (refer to Nitrous Section for more description)
B. Main Menu
The Main Menu is shown below:

Main ÆFuel Stats

Menu N2O 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). N2O Menus for optional Boondocker Nitrous kit (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 four Fuel adjust screens (examples shown below). The first screen comes up after selecting Fuel.

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

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805

www.boondockers.com –	email: [e-mail] – fax: [phone]
Revised 05-07-07	Page 3 of 16

Fuel screen1:	M1L	ID LO MD			Fuel screen5:	M1L	-4 -2 +4 +8
	3000 00		00	00		TboL	00 00 00	00
Fuel screen2:	M1L	LO MD HI			Fuel screen6:	M1L	12 16 20	24
	6000 00 00 00					TboH	00 00 00	00
Fuel screen3:	M1L	LO MD HI			Fuel screen7:	M1L	AM DR Sens
	8500 00 00 00					ACEL	00 00 00
Fuel screen4:	M1L	LO MD HI
	10K5 00 00 00

The fuel adjustment rpm ranges are blended as shown in the picture above. This allows for a broader range of adjustments with fewer steps. Each fuel setting is centered at a particular rpm value, in this example: 3000, 5000, 6700, 7800, 8100rpm. Each region is blended with the region below and the region above it as shown. For example, if the rpm is at 4000, the adjustment value will be half the value of the 3000 setting plus half the value of the 5000 setting.

1.A Fuel: RPM Adjustments	M1L ÆLO MD HI
	3000	00	00	00

M1L This displays current map that is being used – in this case, M1 stands for Map1. Five possible fuel maps can

be used. Each map consists of all your configuration and fuel settings for a particular setup. The “L” indicates that this map is Locked – this means the settings cannot be changed (the up/down buttons have no effect). If the map is Unlocked, adjustments can be made to any setting and these changes will be automatically saved to the selected map. Refer to the Load/Copy sections for more details about how to lock and unlock individual maps.

3000 This is the RPM Region for the fuel adjustments on this screen. For this example, this screen’s adjustments

will be centered at 3000rpm. There are usually 5rpm regions (some boxes with special programming will have additional regions). The effect of the 3000rpm setting tapers off until 5000rpm as shown in the picture above, while the effect of the 5000rpm setting is ramping up. The other regions work similar to this.

ID (3000 RPM screen only) This adjustment is for Idle (0-2400 rpms). The 3000 LO setting will take over above 2400 rpms.

LO This adjustment is for Low load conditions. This will affect throttle settings from approximately 0 up to 1/3.

For rpm region 3000, this adjustment will affect idle. For other rpm regions, this will affect deceleration and light-load cruising conditions.

MD This adjustment is for Medium (mid-range) load conditions. This will affect throttle settings from approximately 1/3 up to 2/3.

HI This adjustment is for High load conditions. This will affect throttle settings from approximately 2/3 to full open.

Note 1: Each number is equal to about 1/2% of the total available fuel. The maximum available fuel will vary with each engine as well as with elevation and air temperature.

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805

www.boondockers.com –	email: [e-mail] – fax: [phone]
Revised 05-07-07	Page 4 of 16

Note 2: It is possible to max the injector (duty cycle > 100%) before the adjustment setting is maxed! Pay careful attention to EGT’s, O2 readings, and fuel pressure when running with engine mods that require a lot of additional fuel!

1.B Fuel: Boost Adjustments

Screen 6 (Turbo Low Boost)

M1U -4 -2 +4 +8

TboL 00 00 00 00

This menu adjusts the fuel according to the pressure transducer. Fuel can be added or subtracted as follows: -4: fuel adjustment when pressure is below -2 in Hg (normal idle)

-2: fuel adjustment when pressure is between -2 and 0 in Hg

+4: fuel adjustment is centered at 4 psi. If pressure is below 4, fuel is blended with -2 setting. If pressure is above 4, fuel is blended with +8 setting.

+8: fuel adjustment is centered at 8 psi. If pressure is below 8, fuel is blended with 4 setting. If pressure is above 8, fuel is blended with 12 setting.

Screen 7 (Turbo High Boost)

M1U 12 16 20 24

TboH 00 00 00 00

12:fuel adjustment is centered at 12 psi. If pressure is below 12, fuel is blended with 8 setting. If pressure is above 12, fuel is blended with 16 setting.

16: fuel adjustment is centered at 16 psi. If pressure is below 16, fuel is blended with 12 setting. If pressure is above 16, fuel is blended with 20 setting.

20: fuel adjustment is centered at 20 psi. If pressure is below 20, fuel is blended with 16 setting.

24:fuel adjustment is centered at 24 psi. If pressure is below 24, fuel is blended with 20 setting. If pressure goes above 24psi, fuel is kept at this setting.

1.C Fuel: Accel Pump Adjustments		M1L ÆAM DR Sens
		ACEL 00 00 00
AM	Amount of fuel to be added/subtracted during		.
		acceleration
DR	Duration in engine cycles to make acceleration adjustment
Sens	Accelerator pump Sensitivity. Larger values are Less sensitive (throttle must be moved more). Value of
	Zero will cause accelerator pump to always be on! Typical values are between 5 and 20.

2. Map / Setup Menus

From the Main Menu, select Map1U to go to the Map Menu (shown below). This screen is used to Load/Copy/Lock/Unlock saved “maps” that contain fuel and N2O settings. Five maps can be used (Map1-Map5).

Lock ULock StUp

ÆLoad Copy Quit

2.1Map: Load

When a new map is loaded, the current adjustment settings will be changed to the values from that map. To load a new Map, first move the cursor to select Load and press “SEL”. The following Load/Lock Menu will be displayed:

Load 1 2 3 4 5→Q

Lock L U U U U Q Load 1-5 Selects which map to load

Lock	L = Locked, U = Unlocked, applied to the map number the L or U is under
Q	Quits this menu
BoonDocker	– 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805
www.boondockers.com – email: [e-mail] – fax: [phone]
Revised 05-07-07	Page 5 of 16