BoonDocker POLARIS: Non-turbo Control Box 600/700/800 Universal Harness User Manual
Fuel + n, O, tps), Kit contents
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Document Outline
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- Polaris 600/700/800 EFI Control Box Instructions
- Kit Contents:
- II. Control Box Harness Installation
- 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.
- 5. Power wire:
- 6. Injector wires:
- 7. TPS wire: If installing a nitrous kit, use the white wire on the N2O harness, otherwise, use the white wire on the supplied TPS connector.
- 8. 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!
- 9. Heat shrink all the splice connectors.
- 10. 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.
- 11. Install the plastic clutch cover.
- 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.
- Kit Contents:
- 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:
- 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
- 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).
- 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
- 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.
- 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.
- 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.
- 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:
- Lock L 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
- Q Quits this menu
- 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, the Mx (x is the map number) that is displayed in the Main and Fuel menus will show the loaded map number as a reminder.
- To copy a map, first select Copy from the Map Menu. The following Copy/Lock Menu will be displayed:
- Lock L 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 to be 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:
- Select Q to Quit and return to the Main Menu.
- Run “Run” indicates display is in Run mode. If in capture mode, “Cap” will be displayed.
- 35 Input duty cycle in percent
- 40 Output duty cycle in percent
- F 10 Fuel adjustment
- MD Engine Load. LO, MD, or HI will be displayed.
- These max values will be saved when the box is shut off so they will remain the next time this screen is displayed even if the box is re-powered. Peak values or “spikes” are filtered by finding the average during a certain time-window. Therefore, a maximum must be held for at least 1 second to be recorded and displayed properly.
- Use the arrow keys to move the cursor between Y and N. Pressing SEL when the cursor is on Y will clear the max values. Pressing SEL when the cursor is on N takes you to the next screen: Stats: N2O/DC.
- N2O 32 Maximum fuel adjustment during last nitrous activation (blacked out █ █ █ during nitrous activation). This can be cleared manually and is always clear upon next nitrous activation.
- PSI 240 For systems without a N2O pressure regulator (NON in lower right-hand corner of Startup Screen), this displays current nitrous tank pressure. For systems using a N2O pressure regulator (ADJ or FIX in lower right-hand corner of Startup Screen), this shows the maximum nitrous pressure during the shot, where the pressure is measured after the solenoid valve. The maximum is averaged over a 1 second period.
- MxTP 208 Maximum throttle position reading since this menu was last cleared or since engine was last started.
- Selecting Y will clear these values. Use any arrow key to select Y or N. Pressing “SEL” takes you to the Main Menu.
- VI. EFI Tuning Suggestions
- Each Fuel adjustment setting goes from –99 to 127. Positive numbers add fuel and negative numbers subtract fuel. The Control Box will not prevent a lean burndown! You must take the proper tuning steps the same as if you were tuning a carburetor.
- The maximum is set to 127. This does not mean you have an effective range all the way to 127 – you will likely max out the injector before this setting is reached. Your usable adjustment range (max value) is dependent on how long the ECU already has the injector on. This will vary depending on rpm, throttle setting, temps, and can be different from sled to sled even of the same model. There is no direct relation
- VI. Nitrous Tuning (for optional Boondocker Nitrous kit)
- VIII. Control Box Troubleshooting
- Stuck Button
- Injector Errors
- Other Issues