BoonDocker POLARIS: Non-turbo Control Box 600 IQ 2 INJ User Manual
Page 2
BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805
www.boondockers.com – email:
– fax: 208-524-7381
Revised 2-13-08
Copyright © 2004-2008 by Boondocker
Page 2 of 19
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: You must install a TPS wire. If you
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).
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