BoonDocker Nytro Turbo User Manual

Yamaha Nytro Turbo 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 Transducer
___1 EFI harness ___ 1 Transducer bracket
___1 3 Wire 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 (Engine 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 add or subtract fuel amounts for certain rpm ranges and load conditions. This is done by using the
buttons and LCD display to change its fuel adjustment settings. 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 Mixture
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 Silicone Dielectric Grease on all connections to help prevent corrosion on the terminals.

This is available from automotive supply stores, commonly labeled as “Light Bulb Grease”.

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 can 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

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II. Wiring:

A. Injector Harness:

The pigtail pairs of the Control Box EFI wiring harness plug
in between the injector connectors from the stock harness and
the injectors. Starting with the shortest pair of connectors
(yellow and tan wires), plug these into the injector for cylinder
#1 (PTO side). Continue with the middle pair, then plug the
longest set of wires injector for cylinder #3 (MAG side).

The white connector connects to the Control Box. Route this
harness to keep it away from heat and moving parts. Use zip
ties to secure it in place.

B. Turbo Harness

Note in the picture below where each connection goes. Route this harness so that the Control Box connector is adjacent to
the Injector Harness Control Box connector. Route the other wires as required. Keep the harness away from heat and
moving parts. Use zip ties to secure it in place. The auxiliary power source will be covered in the next section.

Connect the yellow wire on the Turbo Harness to the yellow TPS wire on the stock harness as described below. It can be
spliced in near the TPS switch or near the large gray 16-pin connector (14 wires used) near the top left in the engine
compartment. (Connecting this wire is not mandatory if you don’t want to use throttle position to trigger nitrous injection.)

Note on using the supplied butt splice connector: If installed correctly, this butt splice will provide a reliable connection.
Be sure to use a quality crimping tool. DO NOT USE A CRIMPER THAT PUNCHES INTO THE INSULATION. DO
NOT USE PLIERS. After crimping you will use heat to shrink the insulation. Adhesive inside the connector will melt and
flow around the wires, which will hold the wire and seal out moisture.

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

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1. Choose your location to connect the wire.

2. Cut the stock yellow wire and strip the ends ¼”. Do not cut closer than 2” from any connector to allow working

room and to allow extra length for mistakes.

3. Cut the Boondocker Turbo Harness yellow wire to the appropriate length, leaving a little working leng th. Strip

this wire ¼”.

4. Twist one of the yellow wires from the sled’s harness together with the yellow wire from the Turbo Harness,

insert into one end of the butt splice, and crimp. Insert the remaining wire into the other end of the butt splice and
crimp. (Two wires will go into one end of the butt splice connector and one wire will go in the other end.)

5. After crimping, pull on the wires to be sure they are securely crimped.

6. Apply heat to shrink the connector’s insulation tightly around the wires.

7. If you have an optional N2O button, mount it, route the wires, and plug it into the connector on this harness.

C. Auxiliary Power Harness

The harness shown to the left plugs into the sled’s
auxiliary power circuit. Near the top left of the engine
compartment is a connector having a black wire and an
orange wire with a black stripe. Plug one of the white
connectors from the Boondocker Auxiliary Power
Harness into this. If there is already something
connected here, unplug the connector and plug the
white connectors from the Boondocker Auxiliary
Power Harness between the existing connectors. One
of the molded rubber plugs is for the turbo oil pump.
The other molded plug provides power to the auxiliary
injectors. Plug it into the molded rubber connector on
the turbo harness.

IMPORTANT: Perform the following two tests (Parts D and E) after the Turbo and Auxiliary Power Harnesses
have been installed to verify that installation is correct!

D. Auxiliary Injector Test:

1. Start the sled and check for fuel leaks.

2. Using the Control Box, go to the N2O menu. (From startup menu, press “SEL”, cursor to “N2O,” and press

“SEL.”) The screen should appear as shown below. Set the Fuel value to 50, TPS to OFF, RPM to OFF, and
Btn to N2O. (Refer to Section VI, parts 1 and 2 for instructions on how to do this.)

Fuel TPS RPM Btn

Æ050 OFF OFF N2O

3. If you have an optional N2O button, press it. This should immediately add fuel through the auxiliary injectors.

You should notice the engine load up with fuel. If you don’t have a button, use a small piece of wire or a paper
clip to jump between the two terminals on the Turbo Harness Button Connector (yellow and tan wires).

E. Oil Pump Test

1. Be sure there is oil in the turbo reservoir.

2. Disconnect the top oil line from the turbo.

3. Hold the oil line over a container and start the sled.

4. Hold the sled RPMs above 3000 for 10 seconds. A thin stream of oil should be observed flowing from the line.

5. If no oil is seen, verify that the voltage into the oil pump is between +12 and +15V DC when the engine is revved

up (red lead on terminal for red wire). If so, then feel the pump to see if it is vibrating.

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

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F. 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
Boondocker injector harness (9-volt battery is not
required). This reconnects the injectors to the ECU,
bypassing the Control Box. This is for emergency or
diagnostic use only! Do not use nitrous or allow engine
to build boost as no extra fuel will be added and engine
can be damaged!

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 or a little higher.

If the box is mounted under the hood, keep the box away from
excess heat, including radiant heat. Also keep the box 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 which map was last selected and what its settings are – you do not need to do anything to save a
map when making adjustments (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:

FX Nytro Turbo .
4B5iBD N2O:FIX

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

FX Nytro Turbo Sled model and application. This box is designed for the Yamaha Nytro with a

turbocharger. Boxes for other sleds will have other lettering.

4B5iBD

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)

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

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

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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). Here you can tune according to RPM and turbo boost.
Stats Display runtime data, captured data, and recorded maximum data (see Section 3).
N2O Go to the configuration menus for optional Boondocker Nitrous kit (see Chapters VII and IX..).
Map Go to the Map management menu (see Section 2). Additional nitrous configuration and tuning factors

are also found by selecting MapXX and StUp.

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

From the Main Menu, select FUEL to make adjustments for RPMs, turbo boost, and accelerator pump.

1.a RPM-based Tuning – There are four RPM-based Fuel adjust screens (examples shown below). The first screen

comes up after selecting Fuel from the Main Menu.

Fuel screen1: M1U Id LO MD

3000 00 00 00

Fuel screen2: M1U LO MD HI

5000 00 00 00

Use the Left/Right Arrow keys to switch between the LO/MD/HI load ranges. Use the Up/Down Arrow keys to change
the fuel settings. Go to the next adjustment screen by pressing the “SEL” button. After pressing the “SEL” on the last
RPM-based Fuel adjust screen, you will go to the first turbo Fuel adjust screen.

The RPM-based fuel adjustments can be made according to the following two factors: RPM and Engine Load.

RPM Regions:

Four or more RPM regions are pre-programmed into the control box which allow fuel adjustments to be made at specific
RPMs. Whenever the engine RPMs are between these specific RPMs, the fuel adjustment will be the result of the adjacent
RPM fuel settings blended together proportionately. For example, the fuel setting at 5000 RPM is centered at 5000 RPM,
but this value also has an affect on fuel whenever RPMs are above 3000 RPM and below 7000 RPM (the two adjacent
settings for this example). Suppose the 3000 fuel setting is at “4” and the 5000 fuel setting is at “8”. If engine RPMs are at
4000 (mid way between 3000 and 5000) the actual fuel adjustment made will be “6”, which is mid way between “4”and
“8”.

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 (idle) 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 screen3: M1U LO MD HI

7000 00 00 00

Fuel screen4: M1U LO MD HI

8500 00 00 00

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

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Making RPM fuel 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 Section 2 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. The effect of the 3000rpm setting decreases until 5000rpm, while the effect of the
5000rpm setting increases as RPMs go towards 5000. The other regions work similar to this.

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

LO,MD,HI The fuel added or subtracted in each RPM region depends upon engine load. A different fuel number

can be entered for each load (low, medium, or high). Since engine load is directly related to throttle
position, each load range is equivalent to the following approximate throttle positions:

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 (from the stock
ECU) will be passed through unmodified. Negative values will reduce the fuel. Positive values will increase the
fuel.

Note 1: Each number is equal to about 1/2% of the total available fuel from the stock injectors. 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/mixture readings, and fuel pressure when running with engine modifications that require a
lot of additional fuel!

1.b Turbo Tuning – There are two turbo adjust screens (examples shown below). These are in the Fuel Menu and

appear following the four RPM screens.

Turbo screen1: M1U -4 0 +4 +8

TboL 00 00 00 00

Turbo screen2: M1U 12 16 20 24

TboH 00 00 00 00

Use the Left/Right Arrow keys to switch between boost ranges. Use the Up/Down Arrow keys to change the fuel
settings at a given boost pressure. Go to the next adjustment screen by pressing the “SEL” button. After pressing the
“SEL” on the second turbo adjust screen, you will go to the accelerator pump menu.

The first turbo screen is for adjusting fuel for low boost pressures (-4 to 8psi), and the second is for high boost pressure s
(12 to 24psi).

Note that in the upper left-hand corner, the current Map number is shown (M1) along with whether it is locked (L) or
unlocked (U). Across the top of each screen is the boost pressure range. Across the bottom of each screen is the user­adjustable fuel number. For any boost pressures between the values displayed, the actual fuel quantity is computed
proportionately. The value at -4psi (-2”Hg) is used for any pressure below -4psi. The value at 24psi is used for any
pressure over 24psi. Therefore, do not allow a boost pressure over 24psi as it will run too lean.

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

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

Revised 2-13-08 Copyright © 2004-2008 by Boon docker Page 6 of 20