BoonDocker POLARIS Non-turbo Control Box 600 IQ 2 INJ User Manual

Polaris 600 2009 2 injector EFI Control Box Instructions

(Fuel + N2O, TPS)

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

Kit Contents:

Quality check by:

___1 Control Box
___1 EFI Harness

___1 battery/ jumper connector ___1 Advanced mode instructions

___5 red butt-splices (1 is spare)
___3 blue butt-splices (1 is spare)

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!

Note 1: 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 TPS Harness (if w/o nitrous)
___1 reusable zip-tie

II. Control Box Harness Installation

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 optional Nitrous wiring 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

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

The EFI harness has wires that will be hard-wired into
your sled’s injector harness.

IMPORTANT:
are installing a nitrous kit at the same time, this wire
will be included with the nitrous kit. If you are not
installing a nitrous kit, you will need to install the
white TPS wire which is by itself on a separate
connector that plugs into the Control Box N2O
connector (see photo).

You must install a TPS wire. If you

The EFI harness will need to be connected to your sled’s harness as follows:

1. Remove the plastic clutch cover.

2. 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.

3. 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 heat and moving parts.

4. If the sleeve over the Boondocker 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 heat-shrinking 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. DO NOT USE
PLIERS. 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.

Crimp/Heat-Shrink

Connector Installed

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5. Power wire:

Boondocker EFI Harness

Red

Sled Injector Harness

Red/Blue

Use a blue Crimp/Heat-Shrink Connector to attach the Red power wire to the Red/Blue wire (position 3) on the
sled’s harness. Cut the Red/Blue wires on the sled’s harness, 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 Red/Blue wire into the other end of the connector and
crimp. (Note that the stock connection has not been interrupted in this hookup.)

6.Injector wires:

Boondocker EFI Harness

Yellow
Tan
Green
Brown

Sled Injector Harness
Yellow/white on ECU side
Yellow/white on Injector side

Darker blue/white on ECU side
Darker blue/white on Injector

side

Caution: There are 2 yellow/white wires on the 26-pin
connector. Be sure to use the yellow/white wire in

position 15

position numbers are molded into the rear of the ECU
connector.

on the 26-pin ECU connector. The

Note: The Yellow/white wire is in position 15 and the dark blue/white wire is in position 2 in the 26 pin connector.

a. Cut the injector wires (yellow/white and dark blue/white) leaving enough working room on both ends. Strip

these wires about 3/16”. Be sure these wires don’t have any tracer colors (stripes) on them.

b. Cut the Yellow, Tan, Green, and Brown EFI harness wires to length, leaving a little extra length. Strip these to

about 3/16”.

c. Note that two of the injector harness wires go to the ECU and two go to the injectors. Use red Crimp/Heat-

Shrink Connectors to connect to the four wires as listed above. (Note that the stock connections have been
broken so that the signals from the ECU go only to the Control Box and the Control Box directly drives the
injectors.)

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

supplied TPS connector.

Boondocker N2o/Aux Harness

White or Pink

Sled Injector Harness

Light Blue (position 7)

Use a 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 leaving 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. (Note that the stock connection
has not been interrupted in this hookup.)

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 sleeve 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!

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805

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

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8. Heat shrink all the splice connectors.

9. Double check the harness routing to be sure it is away from heat 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.

10. Install the plastic clutch cover.

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 Plug-in box plug in the Jumper connector. This
will connect the injectors 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

Every time 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 is shown below:

Polaris 600-700

xxxxxxxx N2O:ADJ.

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

Polaris Sled make
600-700 Sled model Note: Be sure the Control Box is for your make and model of sled!
xxxxxxxx Code Version This is the version of code in the box. The version of code can only be changed

N2O: Shows that this Control Box is nitrous capable.

by sending the box back to Boondocker.

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805

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

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ADJ Nitrous pressure regulator type (if used). This mode is described below in the Nitrous Section.

2. 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.
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

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

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.

Fuel screen4: M1L LO MD HI tr

7800 00 00 00 00

Fuel screen5: M1L LO MD HI tr

8100 00 00 00 00

Fuel screen6: M1L AM DR Sens

ACEL 00 00 00

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805

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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:

M1L This displays current map that is being used – in this case, M1 stands for Map1, and L indicates the map is

Locked (changes are not allowed). Five possible fuel maps can be used. Each map consists of all the fuel

settings for a particular setup. If the map is Locked, the settings cannot be changed and the up/down buttons
have no effect. If U is displayed, 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, Unlock, Load, and Copy different 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 can be from 3 to as many as 7 rpm regions depending on the program version.
The effect of the 3000rpm setting tapers off until 5000rpm, while the effect of the 5000rpm setting ramps up as

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

rpms go towards 5000. The other regions work similar to this.

throttle position, each load range is equivalent to the following approximate throttle po sitions:

LO = 0 up to 1/3 throttle
MD = 1/2 up to 2/3 throttle
HI = 2/3 up to full throttle

tr This adjustment is to Trim the PTO cylinder (injector connector with green/brown wires). This is used to add

or subtract fuel on the PTO 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).

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 in crease the fuel.

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 running with engine mods that require a lot of
additional fuel!

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805

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

Revised 2-13-08 Copyright © 2004-2008 by Boon docker Page 6 of 19