BoonDocker Phazer User Manual

Yamaha Phazer 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 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.

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. EFI Harness

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
go to the MAG side, and the connector pair with the Green and Brown wires go 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, 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.

B. Pressure Transducer wiring:

The pressure transducer is used to determine manifold
pressure (vacuum or boost).

1. Connect the pressure transducer so it is Tee’d into

the manifold vacuum line (same hose that goes to
MAP sensor). The pressure transducer can be
mounted to the frame with the supplied mounting
bracket.

2. Plug the transducer connector into the transducer.

3. The white connector from the transducer harness

plugs into 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 2 of 16

C. 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 jum per 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 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.

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:

Phazer Turbo
4B5gBD N2O:FIX

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

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

4B5gBD This is the software version of the box. The box can be reprogrammed only by sending

have other lettering.

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]

Revised 05-07-07 Page 3 of 16

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).

Fuel screen1:

3000 00 00 00 00

Fuel screen2:

6000 00 00 00 00

Fuel screen3:

8500 00 00 00 00

Fuel screen4:

10K5 00 00 00 00

M1L LO MD HI tr

M1L LO MD HI tr

M1L LO MD HI tr

M1L LO MD HI tr

Fuel screen5: M1L -4 -2 +4 +8

TboL 00 00 00 00

Fuel screen6:

TboH 00 00 00 00

Fuel screen7:

ACEL 00 00 00

M1L 12 16 20 24

M1L AM DR Sens

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 – 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

1.A Fuel: RPM Adjustments M1L ÆLO 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.

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 run ning with engine mods that require a lot of additional
fuel!

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).

1.B Fuel: Boost Adjustments

Screen 6 (Turbo Low Boost)

M1U -4 -2 +4 +8

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,

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

Screen 7 (Turbo High Boost)

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

TboL 00 00 00 00

fuel is blended with +8 setting.

fuel is blended with 12 setting.

M1U 12 16 20 24
TboH 00 00 00 00

12, fuel is blended with 16 setting.

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