BoonDocker Non-turbo Control Box Apex User Manual

Yamaha Apex 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 reusable zip-tie
___1 EFI harness ___1 TPS wire kit (if not in nitrous kit)
___1 battery connector ___1 Advanced mode instructions
___1 jumper connector (4inj)

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 – 2379 Heyrend Way Idaho Falls, Idaho 83402 – 208-542-4411 / 877-522-7805

www.boondockers.com – email: [e-mail] – fax: [phone]

Revised 07-18-07 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.

III. Battery / Jumper Connectors

Two jumpers are supplied with 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 Connector in order
to operate the box without the sled running.

2. Jumper Bypass Connector

The Jumper/Bypass connector can 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 Plug-in box plug in the Jumper connector.
This will connect the injectors directly to the sled’s ECU.

IV. 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.

V. 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).

BoonDocker – 2379 Heyrend Way Idaho Falls, Idaho 83402 – 208-542-4411 / 877-522-7805

www.boondockers.com – email: [e-mail] – fax: [phone]

Revised 07-18-07 Page 2 of 16

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:

Yamaha Apex 1000
v:4B5gBD N2O:ADJ

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

Yamaha Apex Sled model. This box is designed for the Yamaha Apex. Boxes for other sleds will

have other lettering.

4B5gBD 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.
ADJ Nitrous pressure regulator type (refer to Nitrous Section for more description)

B. Main Menu

The Main Menu is shown below:

Main Fuel 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.

Fuel screen1: M1L Id LO MD

3000 00 00 00

Fuel screen2: M1L LO MD HI

6000 00 00 00

Use the Up/Down Arrow keys to change the settings. Use the Left/Right Arrow keys to switch between the LO/MD/HI
settings. Go to the next adjustment screen by pressing the “SEL” button. After pressing the “SEL” on the last Fuel adjust
screen, you will return to the Main Menu.

Fuel screen3: M1L LO MD HI

8500 00 00 00

Fuel screen4: M1L LO MD HI

10K5 00 00 00

BoonDocker – 2379 Heyrend Way Idaho Falls, Idaho 83402 – 208-542-4411 / 877-522-7805

www.boondockers.com – email: [e-mail] – fax: [phone]

Revised 07-18-07 Page 3 of 16

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. The effect of the 3000rpm setting tapers
off as rpms increase towards the 5000rpm region, while the effect of the 5000rpm setting becomes greater. 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.
The other regions work similar to this. If rpms continue above the highest rpm setting, fuel will continue to be adjusted at
the amount of the highest rpm fuel setting.

Fuel Screens (RPM Adjustments) M1L Id 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.

Id (3000 screen only) This adjustment is for Idle only (up to 2000rpm).

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

Note 2: It is possible to max the injector (duty cycle > 100%) before the adjustment setting is maxed (127)! Pay careful

attention to EGT’s, O2 readings, and fuel pressure when running with engine mods that require a lot of additional fuel!

engine as well as with elevation and air temperature.

BoonDocker – 2379 Heyrend Way Idaho Falls, Idaho 83402 – 208-542-4411 / 877-522-7805

www.boondockers.com – email: [e-mail] – fax: [phone]

Revised 07-18-07 Page 4 of 16

2. Map 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 Quit
Load Copy Quit

2.1 Map: 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

Use the Up/Down and Left/Right Arrow keys to move the cursor around. To load a new map, move the cursor to
the desired map number and press “SEL.” The map will be loaded and the Main Menu will be displayed. When a
map is loaded, the Mx (x is the map number) that is displayed in the Main and Fuel menus will show the loaded
map number as a reminder.

To quickly Lock or Unlock maps, move the cursor down to the Lock row, place the cursor under the L or U by the
desired map number, and press “SEL” to change a U (Unlocked) to an L (Locked) or vice versa.

Select Q to Quit and return to the Main Menu.

2.2 Map: Copy

To copy a map, first select Copy from the Map Menu. The following Copy/Lock Menu will be displayed:

Copy 1 2 3 4 5→Q

Lock L U U U U Q

Copy 1-5 Selects which map to copy the current map TO
Lock L = Locked, U = Unlocked
Q Quits this menu

This screen is used to save the CURRENT fuel adjustment map TO one of five available map locations. The map
that is being copied TO must be Unlocked – otherwise a message will be displayed telling you that the map you
selected cannot be overwritten.

Note: When a map is copied, the Control Box will load the map copied TO to be the new current map.

Use the Up/Down and Left/Right Arrow keys to move the cursor to the map number you want to copy TO and

press “SEL”. The following confirmation message will be displayed:

Overwrite Map A

With Map B? YN

“A” represents the map copied TO and “B” represents the current map to be copied FROM. If this is exactly what
you intend, use the Left Arrow to underscore “Y” and press “SEL”. Then the current map will be loaded into the

selected map number, the selected map number will become the current map, and the Control Box will return to the
Main Menu.
To quickly Lock or Unlock maps, move the cursor down to the Lock row, place the cursor under the L or U by the
desired map number, and press “SEL” to change a U (Unlocked) to an L (Locked) or vice versa.

Select Q to Quit and return to the Main Menu.

BoonDocker – 2379 Heyrend Way Idaho Falls, Idaho 83402 – 208-542-4411 / 877-522-7805

www.boondockers.com – email: [e-mail] – fax: [phone]

Revised 07-18-07 Page 5 of 16