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

BoonDocker – 1585 Hollipark Dr. Idaho Falls, ID 83401 – 208-542-4411 / 877-522-7805
www.boondockers.com – email: [email protected] – fax: 208-524-7381
Revised 2-13-08 Copyright © 2004-2008 by Boondocker Page 1 of 19
Polaris 600 2009 2 injector EFI Control Box Instructions
(Fuel + N
2
O, 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 TPS Harness (if w/o nitrous)
___1 reusable zip-tie
___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 when tuning.
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 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.
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.