BoonDocker POLARIS 700-800 IQ Dragon Universal User Manual

Polaris 600/700/800 Turbo EFI Control Box Instructions

(Universal Harness)

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

Control Box Kit Contents:

Quality check by:

___1 Control Box ___10 red butt-splices (2 is spares)
___1 EFI universal harness ___3 blue butt-splices (1 is spare)
___1 Pressure Transducer ___1 battery connector
___1 mounting bracket for transducer ___1 jumper connector

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 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 1-16-08 Page 1 of 14

Crimp/Heat-Shrink

Connector Installed

EFI HARNESS

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 wiring harness 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.

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

The Control Box EFI harness will need to be spliced
into your sled’s harness as follows:

1. Locate the fuel injector harness (see photo).

This harness comes from the smaller (26-pin)
ECU connector. Cut away several inches of the
black sleeve around the harness as shown.

2. Determine where the control box will be

mounted and how the harness will be routed.
Route the harness so the wires end up near the
sled’s fuel injector harness. Be sure to route the
harness away from hot areas and moving parts.

3. If the sleeve over the EFI harness wires is too

long, mark a cutting location, pull the sleeve off
the wires, cut it to length, and reinstall it over
the wires.

Note on using the supplied Crimp/Heat-shrink connectors:

The supplied Crimp/Heat-Shrink Connectors, if installed
correctly, will provide a reliable connection. After the wires
are cut and the insulation is stripped, the connector is crimped
onto the wires. The connector is then sealed by the heat­shrinking process (adhesive inside the connector will melt and
seal out moisture). Proper crimping and sealing is critical to
the reliability of these connectors. When crimping, be sure to
use the correct crimping tool. DO NOT USE A CRIMPER
THAT PUNCHES INTO THE INSULATION. After crimping,
pull on the wires to be sure they are securely crimped. Then

apply heat to shrink the connector’s insulation tightly around

the wires. See example in photo.

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

Revised 1-16-08 Page 2 of 14

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

4. Power wire:

Use the blue Crimp/Heat-Shrink Connector to attach the Red power wire to the Red/Blue wire on the sled’s
harness. Cut one of the Red/Blue wires on the sled’s harness (there are 2 of these, doesn’t matter which one),
leave enough working room on both ends. Cut the Red wire on the Boondocker EFI harness to length, but leave a
little extra length. Strip the insulation from these three wires about 1/4” from the end. Twist together the Red and
one Red/Blue wire, insert into one end of the Crimp/Heat-Shrink Connector and crimp. Insert the other

5. Injector wires:

6. TPS wire: If installing a nitrous kit, use the white wire on the N2O harness, otherwise, use the white wire on the

Red/Blue wire into the other end of the connector and crimp.

Boondocker EFI Harness

Red

Boondocker EFI Harness

Yellow
Tan
Green
Brown

Sled Injector Harness

Red/Blue

Sled Injector Harness

Yellow on ECU side
Yellow on Injector side
Green on ECU side
Green on Injector side

Note: There are 2 yellow wires on the 26-pin

connector. Be sure to use the yellow wire in

position 6 on the 26-pin ECU connector.

Blue Yellow/White on ECU side
Violet Yellow/White on Injector side
Pink Green/White on ECU side
Gray Green/White on Injector side

a. Cut the injector wires (yellow, green, etc) leaving enough working room on both ends. Strip these wires about

3/16”.

b. Cut the EFI harness wires (yellow, tan, green, etc) to length, leaving a little extra length. Strip these to about

3/16”.

c. Note that four of the injector harness wires go to the ECU and four go to the Injectors, be sure to re-verify if you

are connecting to the ECU-side or Injector-side. Use the red Crimp/Heat-Shrink Connectors to connect to the
wires as listed above.

supplied TPS connector.

Boondocker EFI Harness

White

Sled Injector Harness

Light Blue

Use the blue Crimp/Heat-Shrink Connector to attach the White TPS wire to the Light Blue wire on the sled’s
harness. Cut the Light Blue wire on the sled’s harness, leave enough working room on both ends. Cut the White
wire on the Boondocker TPS/N2O harness to length, but leave a little extra length. Strip the insulation from these
three wires about 1/4” from the end. Twist together the White and one Light Blue wire, insert into one end of the
Crimp/Heat-Shrink Connector and crimp. Insert the
other Light Blue wire into the other end of the
connector and crimp.

7. Connect the EFI harness ground eyelet (black wire) to

the grounding stud next to ECU as shown in the picture.
If necessary, cut a slit in the sleeving of the EFI harness
to allow this to reach. This connection must be made
to chassis ground, not the engine ground! A good
ground connection is extremely important!

8. Heat shrink all the splice connectors.

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

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

Revised 1-16-08 Page 3 of 14

9. Double check the harness routing to be sure it is away from hot areas and moving parts. Use zip ties to secure it.

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 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:

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

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Revised 1-16-08 Page 4 of 14

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.
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 engine 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 LO MD HI tr

3000 00 00 00 00

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

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

Revised 1-16-08 Page 5 of 14