BoonDocker POLARIS Non-turbo Control Box 900 IQ User Manual

Polaris ‘05/’06 900/750 EFI Control Box Instructions

(2-Injector Version, Fuel + N2O, TPS capable)

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

Kit Contents:

Quality check by:
___1 Control Box ___1 reusable zip-tie

___1 EFI harness ___1 TPS wire kit (if not in nitrous kit)
___1 battery/jumper connector ___1 Advanced mode instructions

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: 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 3: 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 4: Always use Resistor Spark Plugs! Non-resistor plugs WILL cause electrical interference with the Control Box.

I. 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 optional Nitrous wiring 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 connections to help prevent corrosion on the terminals.

EFI Wiring Harness

On the Polaris, each injector has a short (12”) pigtail that goes to a connector. The EFI harness plugs into these connectors
instead of the injectors themselves since engine removal is necessary to access the injectors. These injector connectors are
located behind the engine under the jackshaft next to the tunnel.

Note for 06 models: The 06 engine has two injectors per cylinder, an Upper and Lower injector for the MAG and

PTO sides. All four connectors are located near the tunnel on the PTO side.
The Boondocker EFI harness will connect to the Lower set of injectors. Each pair of injector wires has one of

the following white identification tags:

LMAG – Lower Mag-side injector connect shorter EFI harness connector to these connectors
LPTO – Lower PTO-side injector connect longer EFI harness connector to these connectors

UMAG – Upper Mag-side injector don’t use
UPTO – Upper PTO-side injector don’t use

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

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

Revised 11-07-07 Page 1 of 16

1. On the 05 model, the PTO side injector
connector is located down below the fuel
pressure regulator. The EFI Harness
connectors with the longer wires connect to
the PTO injector connectors. Unplug the

sled’s connector and reconnect using the EFI

harness connectors.

2. On the 05 model, the MAG connector is
located down between the oil reservoir and
the coolant bottle. It is easier to see the
injector plug-in on the Mag side if you
remove the exhaust and remove the bulkhead
cross-support plate. If needed, you can also
remove the brake caliper. It may also be
helpful to pull up on the coolant lines and
push them onto the cylinder - this will allow
you to more easily see the connector. The EFI
Harness connectors with the shorter wires
connect to the Mag Injector connectors.
Unplug the sled’s connector and reconnect
using the EFI harness connectors.

Be sure each connector is plugged in
correctly. You should hear it as well as feel it click in.

There is very little room. Most people can only fit one hand down in to plug in the injector. Place both parts of the

connector in the palm of your hand and get them started. Then push together with your thumb while holding other
end with your pinky finger.

3. Run the wiring harness down along the oil/water bottle, along the side of the engine and across to the injector
connectors.

4. Connect the ground eyelet for the EFI harness to either the frame or one of the bolts on the engine recoil housing.

II. Box Mounting Locations

The Control Box can be mounted under the hood, on the dash, or on the
handlebars 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 coil.

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

III. Battery / Jumper Connector

The supplied Battery/Jumper Connector has a dual purpose. It can function as a battery connector in order to supply
voltage to the Control Box when the engine is not running, and it can function as a jumper in order to bypass 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 11-07-07 Page 2 of 16

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 /
jumper connector in order to operate the box without the sled

running. This battery connector plugs into the Control Box’s nitrous

connector (refer to picture below). Secure the battery to the
connector with a zip tie in order to provide a strain relief for the 9­volt connector. The battery can also be secured to part of the
harness if it is to be used on the sled while it is running.

The battery connector can be left plugged in during engine
operation, but the nitrous harness (if used) cannot be plugged into
the Control Box. The battery will eventually drain if left connected
to the box, so it is best to disconnect the battery when not in use.

2. Jumper Connector

The Battery/Jumper connector can also 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.

IV. Control Box Menus

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

by sending the box back to Boondocker.

N2O: Shows that this Control Box is nitrous capable.
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 Fuel Stats

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:

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

Menu N2O Map1U

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.

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

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

Revised 11-07-07 Page 3 of 16

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.

3.1 Fuel Screens (RPM Adjustments) M1L LO 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
rpms go towards 5000. The other regions work similar to this.

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

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

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

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Revised 11-07-07 Page 4 of 16

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 increase 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!

3.2 Fuel Screen (ACEL Adjustment) M1U AM DR Sens

ACEL 00 00 00

This is the last screen displayed when in the Fuel menus. This screen is used to control fuel when the control box senses
acceleration (like an accelerator pump). Below is a description for each field show in the above screen:

M1U This displays current map that is being used – in this case, M1 stands for Map1
AM This displays the Amount of fuel to be added (if number is positive) or subtracted (if number is negative)

during Acceleration. This fuel amount will be summed with any other current fuel modifications being made
by the Control Box. This means during acceleration the final fuel adjustment amount will be the amount due
to the Control Box RPM and/or Nitrous settings in addition to the AM fuel setting.

DR This displays the Duration in engine cycles that the fuel shown in AM will modify the existing fuel during

Acceleration. The accelerator pump feature will be turned off if this value is zero and no fuel adjustments will
be made. The Acceleration fuel adjustment will be turned off whenever deceleration is detected (throttle is
backed off) regardless of the DR value.

Sens This displays the Sensitivity that is used to detect engine acceleration. Higher numbers make this Less

sensitive. Do not use zero, or acceleration will be on all the time! Suggested values are between 6 and 20,
start with a value between 8 and 10.

Note: The Stats Screen will display an “A” and a
solid block on the right-side of the screen to indicate
when the Accelerator pump feature is active as
shown:

Stats Screen indicating Acceleration:

Run 35/40 F 10 █
5500 MD █ █ █ A

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 (Map1-Map5) 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 select Load and press “SEL”. The following Load/Lock Menu will be
displayed:

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

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

Revised 11-07-07 Page 5 of 16