BoonDocker Non-turbo Control Box Nytro User Manual

Yamaha Nytro 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 battery / jumper connector
___1 reusable zip-tie

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
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 whe n tuni n g.

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 spra y. 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.

, select “SUPPORT” then select “PRODUCT REGISTRATION”. Please

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

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

Revised 10-31-07 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 #3 (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 t he

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 Control Box can be mounted on the panel below the
handlebars . The box can also be mounted under the hood, on
the dash, or on the handlebars (with custom bracket as shown).
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.

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).

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

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

Revised 10-31-07 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 Nytro
v:4B5gBD N2O:ADJ

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

Yamaha Nytro Sled model. This box is designed for the Yamaha Nytro. 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 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.

Fuel screen1: M1L Id LO MD

3000 00 00 00

Fuel screen2: M1L LO MD HI

5000 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.

The control box allows fuel adjustments to be made according to the following two factors: RPM and Engine Load.

Fuel screen3: M1L LO MD HI

7000 00 00 00

Fuel screen4: M1L LO MD HI

8500 00 00 00

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

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

Revised 10-31-07 Page 3 of 16

RPM Regions:

Up to seven RPM regions are pre-programmed in the control box which allows fuel adjustments to be made at specific
RPM settings (5 regions are shown above). Whenever the engine RPMs are between these specific regions, the fuel
adjustment will be the result of the adjacent RPM fuel settings blended together. For example, the fuel setting at 5000
RPM is centered at 5000 RPM, but this value also has an effect on fuel whenever RPMs are above 3000 RPM and below
6700 RPM (the two adjacent settings for this example). Suppose the 3000 fuel setting is at “4” and the 5000 fuel setting is
at “8”, so if engine rpms are at 4000 the actual fuel adjustment made will be ½ of “4” and ½ of “8” which is “6”.

Load Ranges:

Each RPM Region is split into 3 load ranges: LO (low), MD (medium), HI (high). Each load range is roughly equivalent
to the throttle position divided into thirds: LO is closed throttle (idel) to 1/3 open, MD is 1/3 to 2/3 open, and HI is 2/3 to
full open. During light-throttle conditions (slow cruising or deceleration), the LO RPM settings will be used. During part­throttle conditions (normal or faster cruising), the MD RPM settings will be mostly used. During heavy-throttle conditions
(accelerating or heavy load operation), the HI RPM settings will be used.

Fuel Screens (RPM Adjustments) M1L ÆId MD HI

3000 00 00 00

M1L This displays current map that is being used – in this case, M1 stands for Map1, and L indicates the map is

Locked (changes are not allowed). Five possible fuel maps can be used. Each map consists of all the fuel

settings for a particular setup. If the map is Locked, the settings cannot be changed and the up/down buttons
have no effect. If U is displayed, 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, Unlock, Load, and Copy different 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 can be from 3 to as many as 7 rpm regions depending on the program version.
The effect of the 3000rpm setting tapers off until 5000rpm, while the effect of the 5000rpm setting ramps up as

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

rpms go towards 5000. The other regions work similar to this.

LO / MD / HI These are the engine Load settings for each RPM region. Since engine load is directly related to

throttle position, each load range is equivalent to the following approximate throttle po sitions:

LO = 0 up to 1/3 throttle
MD = 1/2 up to 2/3 throttle
HI = 2/3 up to full throttle

00 Fuel adjustment value. Each setting can go from –99 to 127. Refer to the EFI tuning section for general tuning

guidelines. A value of 00 means no fuel adjustment will be made and the original injector signal will be passed
through unmodified. Negative values will reduce the fuel. Positive values will in crease the fuel.

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.

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!

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

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

Revised 10-31-07 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
ÆLoad 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? YÆN

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

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

Revised 10-31-07 Page 5 of 16