BoonDocker POLARIS 700-800 IQ Dragon Plug Play User Manual

Polaris 600/700/800 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 EFI Plug-in Box ___1 Pressure Transducer ___1 mounting bracket for transducer
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 fu el settings! Use of an Air/Fuel Gauge 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.
___1 Reusable Zip-Tie ___1 battery connector ___1 jumper connector
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 plug-in box and the other is for the transducer harness. These two connectors are keyed (male/female) so only the correct harness will fit into the correct plug-in.
BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805
www.boondockers.com – email: info@boondockers.com
Revised 1-16-08 Page 1 of 13
– fax: 208-524-7381
Install the Polaris Plug-in box as follows. (Note: Use Dielectric Grease on all plug connections to help prevent corrosion on the terminals.)
1. Remove the plastic clutch cover.
Note: For an easier fit, a notch can be cut into the plastic Clutch Cover just below the spark plug holder. This can allow the factory harness wires to be extended slightly further and be more easily routed (see picture below).
2. Unplug the 26-pin factory connector (smaller of the
two) from the ECU.
3. Insert the Polaris Plug-in’s 26-pin connector into the
ECU.
4. Carefully move the factory 26-pin connector and the
attached harness wires out from under the clutch cover area and up towards the steering post as far as possible.
Note:
The ignition coil wires from the 26-pin connector can be moved to allow the 26-pin connector to reach farther.
5. Connect the Factory plug into the Polaris Plug-in box.
6. Orient the Plug-in Box so the white connector is towards the
handlebars. Connect the Control Box to this white connector.
7. Connect the Pink wire from the Plug-in box to the
corresponding Pink wire and connector on the Nitrous harness (or separate TPS adapter if non-nitrous application). This wire is the TPS signal. Note: On ‘08 models, there is also a pink
wire on the sled’s harness. Do not connect any Boondocker wire to this factory wire!!
8. Connect the Ground wire eyelet on the Plug-in box to the
Factory Ground post next to the Sled’s ECU (see picture).
9. Double check the routing of all wires to be sure they are away
fro
m hot areas and moving parts. Use zip ties to secure it.
BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-780 5
www.boondockers.com – email: info@boondockers.com – fax: 208-524-7381
Revised 1-16-08 Page 2 of 13
III. Control Box Mounting Locations
The Control Box can be mounted under the hood, on the dash, or on the handlebar riser 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 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 Connectors
Two jumpers are supplied with 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 Connector in order to operate the box without the sled running.
2. Jumper Bypass Connector
The Jumper/Bypass connector can 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 and when the engine is running. Up to 5 different 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.
1. 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:
Polaris 700Turbo Ver:5.1
In the example shown above, this screen displays the following information:
Polaris700 Sled model. This box is designed for the Polaris 700 Turbo. Boxes for other sleds will have
other lettering.
Ver: 5.1 This is the software version of the box. The box can be reprogrammed only by sending the
box back to Boondocker
2. Main Menu
The Main Menu is shown below:
Main ÆFuel Stats Menu N2O Map1U
BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805
www.boondockers.com – email: info@boondockers.com – fax: 208-524-7381
Revised 1-16-08 Page 3 of 13
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. Stats Display runtime data, captured data, and recorded maximum data. N2O Menus for optional Boondocker Nitrous kit. Map Go to the Map menu.
The current Map number is displayed as “Map1U”. This indicates that map number 1 is being used and it is Unlocked.
3. Fuel Adjust Menus
This selection is used to make fuel adjustments. There are up to seven 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 screen1: M1L LO MD N2 DL
3000 00 00 00 00
Fuel screen2: M1L LO MD HI tr
5000 00 00 00 00
Fuel screen3: M1L LO MD HI tr
6700 00 00 00 00
Fuel screen4: M1L LO MD HI tr
7800 00 00 00 00
The control box allows fuel adjustments to be made according to the following two factors: RPM and Engine Load.
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. 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 en gine 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.
3.1 Fuel Screens (RPM Adjustments) M1L ÆLO MD HI tr
3000 00 00 00 00
Below is a description for each field show in the above sample screen:
Fuel screen5: M1L LO MD HI tr
8400 00 00 00 00
Fuel screen6: M1L -4 -2 0 +1
TboL 00 00 00 00
Fuel screen7: M1L 2 3 12 18
TboH 00 00 00 00
Fuel screen8: M1L AM DR Sens
ACEL 00 00 00
BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805
www.boondockers.com – email: info@boondockers.com – fax: 208-524-7381
Revised 1-16-08 Page 4 of 13
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