BoonDocker POLARIS Non-turbo Control Box 2011-12 PRO RMK 800 User Manual

Polaris RMK Pro Nitrous Fuel 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 TPS Adapter (or optional Nitrous Harness)

I. Theory of Operation:

The Boondocker Fuel 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 adjustments while keeping the basic stock fuel map. This
means the ECU can still compensate for engine speed, throttle position, barometric pressure, engine temperature, ambient
air temperature, etc.

The Fuel Control Box modifies the stock fuel map to compensate for sled or engine modifications. It can reduce or
increase fuel amounts for certain RPM ranges and engine load conditions. This is done by changing its fuel adjustment
settings using the buttons and LCD display. As with tuning a carburetor, it is possible to go too rich or too lean!

The Control Box also activates nitrous delivery (nitrous kit sold separately) and adds fuel to achieve proper air/fuel
mixture. Again, as with tuning a carburetor, it is possible to go too rich or too lean! There are seven different ways to
activate nitrous using such factors as RPM, throttle, and a handlebar button or arming switch.

Other features include the ability to capture and display operational data, store maximum values, 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 TPS Wire
___1 Reusable Zip-Tie
___1 jumper/battery adapter (4A style)

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. 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. Using a blow drier to warm up the surface and Velcro will improve adhesion.

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.

III. 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 TPS wire or optional Nitrous 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 crank position sensors. The EFI Harness is shown below.

Install the EFI Harness and TPS Wire 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 to the white 10-pin connectors on the Fuel Control Box

pigtail and plug it in.

4. 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.

5. If you did not purchase a Boondocker nitrous kit, plug the TPS Adapter into the other white 10-pin connector on the

Fuel Control Box pigtail.

6. If you purchased a Boondocker nitrous kit, follow the kit instructions to install the Nitrous Harness.

7. Refer to the instructions in the TPS wire kit to install the TPS wire. Plug it into the TPS Adapter or Nitrous Harness.

8. 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]

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IV. Battery / Jumper Connector

A battery connector and 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 TPS wire or Nitrous Harness and
plugging in the supplied Battery/Jumper Connector with a 9-volt
battery (not included) INTO THE CONTROL BOX, 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 Battery/Jumper Connector 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 to the stock
fuel quantity. If your sled will not run with the Jumper, then unplug the Boondocker EFI harness above the throttle
bodies and plug the stock connectors together.

V. Control Box Operation

The control box is powered only when the injector power is on which occurs during start-up and when the engine is
running.

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:

Polaris Pro RMK•
5B5jBD N2O:ADJ

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

Polaris Pro RMK Sled model. This box is designed for the Polaris RMK without a turbo.

Boxes for other sleds will have other lettering.

5B5jBD 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]

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2. Main Menu

The Main Menu is shown below:

Main Fuel Stats
Menu N2O Map1U

The current selection is shown by the arrow pointing to the right and by 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.
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. The maps store fuel settings and configuration data such as for nitrous.

3. Fuel Adjust Menus

This selection is used to make fuel adjustments. There are six Fuel adjust screens (examples shown below). Five of them
are for engine fuel according to RPM and engine load conditions and the sixth is to configure an accelerator pump. 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: M1U LO MD HI•tr

3000 00 00 00 00

Fuel screen2: M1U LO MD HI•tr

5000 00 00 00 00

Fuel screen3: M1U LO MD HI•tr

6700 00 00 00 00

Fuel screen4: M1U LO MD HI•tr

7800 00 00 00 00

Fuel screen5: M1U LO MD HI•tr

8400 00 00 00 00

Fuel screen6: M1U AM DR Sens•

ACEL 00 00 08 •

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

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3.1 Fuel Screens (RPM Adjustments)

In the RPM screens (1 through 5), 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. 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
(half way between RPM ranges), 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 (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 Fuel Control Box will use the LO RPM
settings to adjust fuel. During part-throttle 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.

M1U LO MD HI•••

3000 00 00 00•••

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

M1U This displays current map that is being used – in this case, M1 stands for Map1, and U indicates the map is

Unlocked (changes are allowed). (Map storage, retrieval, locking, and unlocking are covered below.)

3000 This is the RPM Region for the fuel adjustments on this screen. In this example, this screen’s values will be

used near 3000RPM down to an idle. The effect of the 3000RPM setting tapers off until 5000RPM, while the

LO / MD / HI These are the engine Load settings for each RPM region. Since engine load is directly related to

effect of the 5000RPM setting ramps up as RPMs go from 3000 toward 5000.

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 will be passed
through unmodified. Negative values will reduce the fuel. Positive values will increase the fuel. Each number
is equal to about ½% duty cycle which is ½% of the total available injector-on time.

3.2 Accelerator Pump

Fuel can be added or subtracted from the stock accelerator-pump fuel quantity. The accelerator pump is activated
when the throttle is moved from a low level to a significantly higher level. The setting parameters are as follows:

M1U AM DR Sens•

ACEL 00 00 08 •

M1U Map 1 is selected and it is unlocked.
AM Amount of fuel to inject per stroke upon throttle activation.
DR Duration of fuel injection counted in strokes.
Sens Sensitivity of accelerator pump activation.

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

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4. Map Menus

From the Main Menu, select Map1U to go to the Map Menu (shown below). This screen is used to
Load/Copy/Lock/Unlock saved “maps” that contain fuel and N2O settings. Five maps are available.

Lock ULock StUp
Load Copy Quit

4.1 Map: Load

When a new map is loaded, the current adjustment settings will be changed to the values from that map. To load a
new Map, first move the cursor to Load and press “SEL”. The following Load/Lock Menu appears:

Load 1 2 3 4 5Q

Lock U U U U U Q

Load 1-5 Selects which map to load
Lock L = Locked, U = Unlocked, applied to the map number the L or U is under

Use the Up/Down and Left/Right Arrow keys to move the cursor around. To load a new map, move the cursor to
the desired map number and press “SEL.” The map will be loaded and the Main Menu will be displayed. When a
map is loaded, Mx (x is the map number) is displayed in the Main and Fuel menus showing which map is loaded.

To quickly Lock or Unlock maps while in this screen, move the cursor down to the Lock row, place the cursor

under the letter under the desired map number, and press “SEL” to change from Locked to Unlocked or vice versa.

Select Q to Quit and return to the Main Menu.

4.2 Map: Copy

To copy a map, first select Copy from the Map Menu. The following Copy/Lock Menu will be displayed:

Copy 1 2 3 4 5Q

Lock U U U U U Q

Copy 1-5 Selects which map to copy the current map TO

Lock L = Locked, U = Unlocked

Q Quits this menu

This screen is used to save the CURRENT fuel adjustment map TO one of five available map locations. The map

that is being copied TO must be Unlocked – otherwise a message will be displayed telling you that the map you

selected cannot be overwritten.

Note: When a map is copied, the Control Box will load the map copied TO as the new current map.

Use the Up/Down and Left/Right Arrow keys to move the cursor to the map number you want to copy TO and

press “SEL”. The following confirmation message will be displayed:

Overwrite Map A

With Map B? Y N

“A” represents the map copied TO and “B” represents the current map (copied FROM). If this is exactly what you

intend, use the Left Arrow to underscore “Y” and press “SEL”. Now the current map is loaded into the selected

map number, the selected map number will become the current map, and the Main Menu will be displayed.

To quickly Lock or Unlock maps, move the cursor down to the Lock row, place the cursor under the L or U by the

desired map number, and press “SEL” to change a U (Unlocked) to an L (Locked) or vice versa.

Select Q to Quit and return to the Main Menu.

4.3 Map – Lock and ULock

Either Lock or ULock (UnLock) can be selected from the Map Menu to quickly lock or unlock the CURRENT

map. Move the cursor to the desired selection and press “SEL”. The box will return to the Main Menu and the

current map will be locked or unlocked when SEL is pressed.

Q Quits this menu

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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