BoonDocker Non-turbo Control Box Phazer User Manual

Yamaha Phazer 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 TPS wire kit (if not in nitrous kit)
___1 EFI harness ___1 Advanced mode instructions
___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, 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 Gauge 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 02-14-07 Page 1 of 17

II. Control Box Harness Connectors

There are two 10-pin connectors at the end of the black cable on the control box. One is for the EFI Harness and the other
is for the optional Nitrous Harness. These two connectors are keyed (male/female) so only the correct harness will fit into
the correct plug-in.

Note: Use Dielectric Grease on all plug
connections to help prevent corrosion on the
terminals.

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.

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

connectors for each injector (see picture). The
connector pair with the Yellow and Tan wires
goes to the MAG side, and the connector pair with the Green and Brown wires goes to 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. The space above each injector is tight – it may help to
rotate the injector 90deg to install the connector, and then rotate it back.

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. Do not force the connectors – check for
bent pins.

5. Connect the Control Box harness ground eyelet to a bolt on the chassis. 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.

III. Control Box Mounting Locations

The Control Box can 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 (like the exhaust), and away from the ignition
coil.

Note: The Control Box is designed to be splash proof. Do not submerge or subject the box to high-pressure spray.

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

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

Revised 02-14-07 Page 2 of 17

IV. 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.

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).

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 Phazer
v:4B5bBD N2O:Adj

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

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

have other lettering.

v:4B5bBD This is the software version of the box. The box can be reprogrammed only by sending

the box back to Boondocker

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

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

Revised 02-14-07 Page 3 of 17

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.

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).

Fuel screen1: M1L LO MD N2 DL

3000 00 00 00 00

Fuel screen2: M1L LO MD HI tr

6000 00 00 00 00

Fuel screen3: M1L LO MD HI tr

8500 00 00 00 00

Fuel screen4: M1L LO MD HI tr

10K5 00 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.

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

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

Revised 02-14-07 Page 4 of 17

Fuel Screens (RPM Adjustments) M1L LO MD HI tr

3000 00 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.

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.

tr This adjustment is to Trim the PTO cylinder (left-side cylinder when sitting on the sled). This is used to add

or subtract fuel on the left side if fine-tuning is desired. The LO adjustment is not affected by the Trim value –
trim is only used for the MD and HI settings. It is best to tune the right (mag) cylinder first then make
adjustments to the left (PTO) cylinder if necessary. If more than a small amount of adjustment is required
(greater than plus or minus 7), check for other problems first (such as incorrect harness connections to the PTO
cylinder).

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

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! Pay careful

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

guidelines.

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 02-14-07 Page 5 of 17

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 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 02-14-07 Page 6 of 17