BoonDocker POLARIS 11-12 PRO 800 Turbo 3D Tuning User Manual

Polaris RMK Pro Turbo Fuel 3D Control Box Instructions

Before you begin, please check kit contents and read all the instructions.

Control Box Kit Contents: Quality check by: ______________________

___1 Fuel Control Box
___1 EFI Harness
___1 Transducer Harness (if not in Turbo Kit)
___1 Transducer (if not in Turbo Kit)

I. Theory of Operation:

The BoonDocker Control Box makes fuel adjustments to an Electronic Fuel Injected engine by connecting between the
Engine Control Unit (ECU) and the fuel injectors. The Control Box makes modifications to the signals being sent to the
fuel injectors to increase/decrease the amount of fuel being injected at certain RPM ranges and throttle positions. The
Control Box only modifies the signals being sent from the ECU so the ECU’s stock fuel maps that compensate for different
operating parameters are still used as a baseline.
The Control Box has the ability to add or subtract fuel to achieve the proper air/fuel mixture, these settings are adjustable
using the buttons and LCD display. It is possible to adjust the air/fuel mixture too rich or lean and too the point that engine
damage can occur. To prevent incorrect tuning it is recommended to use an Air/Fuel gauge and that the user has experience
tuning an engine. In addition to adjusting air/fuel mixture the Control Box has other features such as the ability to capture
and display operational data, control fuel for a nitrous oxide system and save multiple fuel maps.

The Boondocker Fuel Control Box has many other features, such as the ability to capture and display operational data,
control a nitrous oxide system, and save multiple setups.

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.

___1 Reusable Zip-Tie
___1 jumper/battery adapter (4A style)
___1 Temp Sensor (if not in Turbo Kit)

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

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

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II. Installation of Fuel Injection 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 Transducer Harness. These two connectors are keyed (male/female) so only the correct connectors will mate.
However, you must be careful to not cross the 6-pin connectors for fuel injectors (EFI Harness) with the connectors for the
Electronic Boost Controller (EBC), which is available separately. The EFI Harness is shown below.

Install the EFI Harness as follows. Note: Use Dielectric Grease in all connectors to help prevent corrosion on the
terminals.

1. Locate the six-pin connector behind the center of the engine cylinders and just above the throttle bodies. This is the

sled’s EFI harness. Lift the latch to disconnect it.

2. Connect the Boondocker EFI harness between these two connectors.

3. Route the Boondocker EFI harness from this location upward where the white 10-pin connector will later connect to the

Fuel Control Box pigtail connector.

4. Route the cable with the remaining connector to the Auxiliary Injectors and plug it in.

5. Connect the ring terminal on the black wire to a solid chassis ground. It is very important to have good electrical

contact. It must be attached in such a way that it cannot come loose.

6. Double check the routing of all wires to be sure they are away from hot areas and moving parts. Use zip ties to secure it.

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

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

Revised 1-20-11 Copyright © 2010 Boondocker Page 2 of 14

III. Installation of Transducer Harness

Two different transducer harnesses are available depending on if an EBC is being used. Both harnesses are shown below.
Install the harness according to the diagram as shown below.

Transducer Harness with EBC

Transducer Harness without EBC

Install the Transducer Harness as follows. Note: Use Dielectric Grease in all connectors to help prevent corrosion on the
terminals.

TPS

The stock throttle position sensor (TPS) is located on the PTO end of the
throttle bodies. As show in the image on the right.

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

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

Revised 1-20-11 Copyright © 2010 Boondocker Page 3 of 14

IIV. Control Box Mounting Locations

The Control Box can be mounted under the hood, on the console, or on the handlebar riser using the supplied Velcro strips.
Before applying the adhesive strips, thoroughly clean each surface (rubbing alcohol works well). Be sure each surface is
room temperature or higher.

If the box is mounted under the hood, keep the box away from excess heat (like the exhaust), and away from the ignition
coils.

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

IV. Battery / Jumper Connector

A jumper is supplied with the Control Box:

1. Battery Connector

The Fuel Control Box is designed to operate without a battery. It will be
on whenever power is applied to the fuel injectors. However, by

disconnecting the Control Box’s turbo connector and plugging in the

supplied Battery Connector with a 9-volt battery (not included), you can
operate the Fuel Control Box without the sled running.

2. Jumper Connector

The jumper is used for troubleshooting only. If your sled will not run or
will not idle correctly, disconnect the EFI harness from the Fuel Control
Box and plug the Jumper into the Boondocker EFI harness to bypass the

Fuel Control Box. The injectors are now connected directly to the sled’s

ECU through the Boondocker EFI harness. Caution: This is only to be
used to test at an idle. Without the Fuel Control Box, no fuel can be
added for boost pressure so engine damage can result. If your sled will
not run with the Jumper, then unplug the Boondocker EFI harness at the
injectors, and plug the stock connectors onto the injectors.

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
and when the engine is running. Up to 5 different maps can be stored in the box. 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.

1. Startup Screen

When the box is first turned on (by the engine or battery), the Startup screen is displayed. Press any key to go to the
main menu. An example Startup screen display is shown below:

PolarisRMK Turbo
5B2a8N2a N2O:FIX

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

PolarisRMK Turbo Sled model. This box is designed for the Polaris RMK with a turbo. Boxes

for other sleds will have other lettering.

5B2a8N2a This is the software version of the box. The box can be reprogrammed only

by sending the box back to Boondocker. Have this number handy when you
call Boondocker for technical support.

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

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

Revised 1-20-11 Copyright © 2010 Boondocker Page 4 of 14

2. 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 menu option and press the “SEL” key.

Fuel Go to the Fuel adjust menus.
Stats Display runtime data, captured data, and recorded maximum data.
N2O Go to setup menus for optional Boondocker Nitrous kit or to set up the tuning feature.
Map Go to the Map menu to store, lock, or change maps.

The current Map number is displayed as “Map1U”. This indicates that map number 1 is being used and it is Unlocked.

3. Boost Fuel Adjust Menus

This selection is used to make fuel adjustments. There are four Fuel adjust screens (examples shown below). Fuel screen1
will be displayed after moving the cursor to the Fuel selection on the Main Menu and pressing the “SEL” button.

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 setting values. Sample Fuel adjust screens are shown below (actual RPM settings and number of screens may
be different for your model).

Fuel screen: psi LO MD HI

4300 08 10 00

3.1 Fuel Screens (RPM Adjustments)

In the RPM screens (1 and 2), the Fuel Control Box allows fuel adjustments to be made according to the following two
factors: RPM and Engine Load.

RPM Regions:

In the example above, the 3000 screen sets the fuel level for near 3000RPM down to idle. The 5000 screen sets the fuel
level for RPMs near 5000. (Higher RPM fuel numbers are fixed internally, but will actually be dominated by boost fuel
settings.) Between 3000 and 5000, the fuel adjustment will be proportioned between the two settings. For example,

suppose the 3000RPM fuel setting is at “4” and the 5000RPM fuel setting is at “8”. If engine is at 4000RPM, the actual

fuel adjustment made will be ½ of “4” and ½ of “8” which is “6”.

Throttle Position:

Each RPM Region is split into 3 throttle position ranges: closed throttle (idle) to 1/3 open, MD is 1/3 to 2/3 open, and HI is
2/3 to full open.

M1U LO MD HI•••

3000 00 00 00•••

Below is a description for each field show in the above sample screen:

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

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

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