Yamaha Apex ControlBoxInstructions
Yamaha Apex ControlBoxInstructions
Yamaha Apex ControlBoxInstructions
IMPORTANT - PRODUCT REGISTRATION: Please register this product online as soon as possible (if you
do not have internet access, please call us at 208-542-4411). It is required that you register this product so you can receive
technical support, warranty claims, and so you can keep informed of product updates.
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.
Note1: 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.
B. Jumper/Battery Connector
The jumper can be used in one of the following
two ways:
1. A 9-volt battery can be plugged into the
jumper and the jumper can be plugged
into the female connector (pressure
transducer connector must be
unplugged) to power the Control Box.
This allows the Control Box to be
turned on when the engine is off.
5B5jBD This is the software version of the box. The box can be reprogrammed only by sending
the box back to Boondocker
FIX Nitrous pressure regulator type (refer to Nitrous Section for more description)
B. 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 (see Section 1).
Stats Display runtime data, captured data, and recorded maximum data (see Section 3).
N2O Menus for optional Boondocker Nitrous kit (see Chapters VII and IX..).
Map Go to the Map menu (see Section 2)
The current Map number is displayed as “Map1U”. This indicates that map number 1 is being used and it is Unlocked.
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 settings. Sample Fuel adjust screens are shown below (actual rpm settings and number of screens may be
different for your model).
The fuel adjustment rpm ranges are blended as shown in the picture above. This allows for a broader range of adjustments
with fewer steps. Each fuel setting is centered at a particular rpm value, in this example: 3000, 5000, 6700, 7800, 8100rpm.
Each region is blended with the region below and the region above it as shown. For example, if the rpm is at 4000, the
adjustment value will be half the value of the 3000 setting plus half the value of the 5000 setting.
To quickly Lock or Unlock maps, move the cursor down to the Lock row, place the cursor under the L or U by the
desired map number, and press “SEL” to change a U (Unlocked) to an L (Locked) or vice versa.
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:
Overwrite Map A
With Map B? YÆN
“A” represents the map copied TO and “B” represents the current map to be copied FROM. If this is exactly what
you intend, use the Left Arrow to underscore “Y” and press “SEL”. Then the current map will be loaded into the
selected map number, the selected map number will become the current map, and the Control Box will return to the
Main Menu.
To quickly Lock or Unlock maps, move the cursor down to the Lock row, place the cursor under the L or U by the
desired map number, and press “SEL” to change a U (Unlocked) to an L (Locked) or vice versa.
3. Stats Menus
This Control Box has a new feature that allows real-time data to be displayed and captured. This feature can be useful for
tuning or for diagnostic purposes.
2nd line
5500 RPM (note, if the engine is shut off, the last recorded RPM may be displayed)
MD Engine Load. LO, MD, or HI will be displayed.
█ █ █ These bars are a graphic display of LO, MD, or HI as shown below:
LO
MD █ █ █
HI █ █ █ █ █ █
10 Current Fuel Adjustment
Run/Capture mode:
Left-Arrow button : Sets Capture Mode, “Cap” will be displayed and the current data will be frozen on the
display. The capture occurs on the display when the button is released (data will continue to
be captured if the button is held down). It will stay in capture mode (data will remain frozen)
until the Right-Arrow is pressed to return to Run mode or until the Control Box is re-
powered. If the Stats menu is re-entered before the engine is shut off and the box is in
Capture mode, the last captured data will be displayed.
Right-Arrow button: Clears capture mode (captured data will be lost!) and sets Run mode. “Run” will be
displayed and real-time data will be displayed. Note: The Button Mode can also be
configured to Capture the Status screen Press SEL to go to the next screen: Stats: MAX.
MAX:DCIn/Out Clr .
MAX: 5500 Max rpm
5500 35/45 YÆN .
DCIn 35 Max Duty Cycle Input from sled’s ECU.
DCOut 45 Max Duty Cycle Output to the injectors.
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/TPS.
MAX 12.2 This is the average maximum boost amount measured in psi. The boost is averaged during a 1
second window in order to filter out boost spikes. This value should be very close to the actual
sustained boost. If the display shows “XX.X”, the boost value has exceeded the valid range.
Peak 13.4 This is the peak boost value. This is usually higher than the Max boost value by 1 to 2 psi due
to spikes on the boost pressure. If the display shows “XX.X”, the boost value has exceeded the
valid range.
Clr Y N Selecting Y will clear the save PSI Max/Peak values. Use any arrow key to select Y or N.
Pressing “SEL” takes you to the Main Menu.
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
Exhaust Gas Temperature gauges can be an effective tuning tool, but they are not a substitute for reading spark plugs and
piston wash and feeling how the engine runs. Use EGTs only as a backup to verify what you see. They can be misleading
under certain conditions and safe readings can vary greatly from engine to engine depending on such things as probe
placement, fuel, timing, pipe design, porting, etc.
Tuning tips:
Important: Find the settings where your motor runs rich before you decide to go lean!
1. Tune with the engine and pipe at operating temperature. The sled’s ECU will make adjustments as the engine
warms up – you might think the engine needs leaner settings then later realize you are too lean once the engine
warms up.
2. Use the Load/Save Map feature to quickly change and compare fuel settings when testing. This can also be
useful for riding under different conditions. For example, changing elevations or temperatures may require
different adjustments if the stock ECU does not compensate properly for your modifications. For drag racing,
you might want to run richer settings for longer distances than you would for short distances.
3. One method for finding out where a fuel adjustment setting is effective, greatly increase only that setting. Run the
engine to find out when it suddenly becomes too rich – this is where that setting is effective. Be careful – you can
easily flood the motor, especially with LO load or low rpm settings. If this happens, to restart the engine you may
have to pull several times with the throttle held wide open.
4. The Stats Capture feature can be used to determine RPM, and if the load setting is LO, MD, or HI. The nitrous
button can be configured to capture these stats (see nitrous configuration section below). From the Main Menu,
select N2O, set Btn to CAP. Whenever the button is pressed, the Stats: Capture screen will be displayed. The
current stats will be captured when the button is released.
N2O Menu in “Capture” mode:
5. The nitrous handlebar button can be used to add or subtract a preset amount of fuel for interactive tuning purposes
(see nitrous configuration section below). From the Main Menu, select N2O, set RPM and TPS to OFF, set Btn
to TUN and adjust the fuel number as desired for the test (see example menu screen below). When the nitrous
button is pressed, this amount of fuel will be added or subtracted immediately from the current settings for all
rpms and all loads.
N2O Menu in “TUNE” mode:
Fuel TPS RPM Btn
040 OFF OFFÆTUN
A/F Mixture Generally EGT’s get hotter as the motor gets lean, but too lean and the temps can actually drop! It’s like
turning the oxygen up too high on a torch – as oxygen is added, the flame gets hotter to a certain point,
then gradually cools off until it becomes extinguished from too much oxygen.
Detonation Detonation often requires an experienced tuner to detect – in most instances it cannot be heard or
noticed. Careful examination of the piston and sparkplug are required. Watch for melted sparkplug
electrodes, speckling on the sparkplug insulator, or shiny or gray flakes on the electrode which could be
melted aluminum from the piston. If possible, watch the crown of the piston (near exhaust port) for a
pitted or sand-blasted look. EGT’s can sometimes read low during detonation – heat is going into the
cylinder and piston instead of out the pipe.
Timing Timing can affect the pipe temperature. Generally if the ignition is retarded, more heat will build up in
the pipe. Too much advance may drop EGT temps, but increase cylinder temps.
Fuel Different fuels have different densities and other characteristics which can affect your mixture and fuel
requirements. Oxygenated fuel will run leaner. Octane rating is important for highly modified motors.
Lean spots Sometimes a motor runs hot at certain rpms and throttle positions (usually in its mid-range) no matter
what. The fuel adjustment settings can be used to richen this up, but the engine may quickly become
too rich and run erratic. Under light load conditions you can sometimes get away with running hot for
short periods of time. Under such conditions it is best to vary the throttle position often and not stay at
one throttle setting for long durations.
On the startup screen (displayed when first powered on), note the message in the lower right-hand corner.
ADJ – Configured for a nitrous system using an Adjustable or Fixed N2O pressure regulator.
Note: Do not use ADJ mode for Control Boxes programmed with Boost capabilities.
FIX – Configured for a nitrous system using a Fixed N2O pressure regulator.
NON – Configured for a nitrous system that is Non-regulated.
Be sure that this description matches your actual nitrous system. Some internal settings and some user menus and settings
are affected by this configuration. Do not attempt to run a Non-regulated nitrous setup with the Control Box in ADJ
mode or a Regulated nitrous setup in NON mode! Please call Boondocker if your setting is incorrect. If you do not
have nitrous capability, then this configuration does not matter.
Note 1: The RPM and Nitrous fuel adjustments are summed. Therefore, any changes made to RPM fuel settings will
affect the quantity of fuel delivered for nitrous. Therefore, for example, if the 7800 HI fuel setting is decreased
by X amount, you need to increase the nitrous fuel setting by X amount in order to get the same total fuel delivery
for nitrous.
Note 2: After initial tuning, any new performance enhancements to your engine will require re-tuning the EFI and nitrous
fuel delivery.
1. Button only: Pressing the momentary button activates the nitrous and releasing the button turns it off. The
button can be configured to activate the nitrous regardless of TPS or RPM conditions.
2. TPS (Throttle Position Sensor) only: When the throttle is pressed beyond a point set by the user, nitrous is
activated. Nitrous is deactivated when the throttle returns to a point below the chosen threshold.
3. TPS and RPM: When the RPM and TPS are within a range set by the user, nitrous will activate. Nitrous will
turn off when the throttle is decreased (TPS is below the adjustable threshold) or when the RPM is out of the
selected range (lower than Min or higher than Max).
4. Button (N2O) or TPS: The handlebar button can be used in combination with the TPS. In this way, either the
throttle or the button can activate the nitrous. The button will always activate nitrous regardless of the TPS
condition.
5. Button (N2O) or TPS and RPM: The handlebar button can be used in combination with the TPS and RPM
range. In this way, either the throttle/RPM or the button can activate the nitrous. The button will always activate
nitrous regardless of the TPS and RPM conditions.
6. Button (ARM) and TPS: The nitrous button input on the Control Box can be used to quickly arm and disarm
nitrous capability. When armed (button input is on), the system can be configured to activate with TPS.
Optionally, the handlebar button, which is momentary (only activated while pressed), can be replaced with a
toggle, rocker, or slide switch so it remains in the on or off position (when not pressed).
7. Button (ARM) and TPS and RPM: Same as option 6 above except with RPM capability. When armed (button
input is on), the system can be configured to activate with TPS and RPM.
From the Main Menu, select the N2O option. Below is a description of this menu:
Delay 000 Delay in number of engine cycles from when nitrous is activated to when fuel is delivered.
Use this feature to reduce any bog that occurs due to fuel being delivered before nitrous
arrives in the engine.
TPS: To select throttle-position triggering, move the cursor until it is under TPS and press “SEL”, Up or Down
Arrow. The following screen will appear:
TPS N2O on if
ÆOFF TPS > 200
TPS OFF Shows TPS mode is OFF.
200 TPS threshold value.
Under TPS, press the Up or Down Arrow to toggle the TPS mode ON or OFF.
Move the cursor right to the 200 setting, then use the Up and Down Arrows to select the trigger level. This
number is set to near 200 at the factory. You can adjust it from 50 to 248.
RPM: To select rpm triggering, move the cursor right until it is under RPM and press “SEL”, Up or Down Arrow.
The following screen will appear:
. RPM Min Max
OFF← 5050 7550
RPM OFF Shows RPM mode is OFF.
5050 Min RPM threshold
7550 Max RPM threshold
Under RPM, press the up or down button to turn this mode ON or OFF.
Move the cursor right to adjust the Minimum RPM (nitrous will be on above this level) and the Maximum
RPM (nitrous will turn off above this level).
Note: To use this mode, TPS must also be ON and the TPS trigger threshold set.
BTN: To select the button mode, move the cursor right until it is under Btn. Press the up or down key to select
between the following five possible modes. The screen will change to the following:
OFF: Description: Btn
Button Off :ÆOFF
This mode disables the handlebar button.
Nitrous activation idea: One way to use the button for nitrous activation and to have the RPM limiting feature
(to prevent hitting the rev-limiter), set Btn to ARM, TPS to ON (with a low threshold), and RPM to ON (with
desired Min/Max settings).
Press the Left or Right Arrow to return to the N2O menu or push the “SEL” button to return to the Main
Menu.
Note: A common problem is a bad ground connection on the sled causing the box to keep resetting itself. If a button
is being pressed when this occurs, the “button stuck” message will be displayed. Start the sled without pressing a
button and see if the message goes away. If it is not present, start looking for a disconnected ground on the sled (see
Other Issues below).
If a button really is stuck on, the Control Box can still function and adjust fuel properly. The Control Box can be sent
back to Boondocker to be serviced.
Injector Fault
The Control Box monitors the signals from the sled’s ECU. If it detects signals on one set of wires but not the other, it
will detect a fault on that injector and display one of the two error messages.
Injector 1 Fault! Missing or bad signal detected on Injector #1 (yellow wire).
Injector 2 Fault! Missing or bad signal detected on Injector #2 (green wire).
Injector 3 Fault! Missing or bad signal detected on Injector #3 (blue wire).
Injector 4 Fault! Missing or bad signal detected on Injector #3 (pink wire).
Injector x Fault! This means a previous injector fault has occurred which has not yet been
cleared. (Press any button when error message is displayed to clear the fault)
If any of these conditions occur, the Control Box will still function and it will still try to make fuel adjustments, but
the intermittent injector connection will need to be fixed. Contact Boondocker to determine if the Control Box and
harness need to be sent back to be inspected or serviced.
Note: Injector errors that occur infrequently can be ignored since they are likely caused by sporadic electrical noise.
2. Verify that the EFI Harness Ground Wire has a good connection.
3. Verify that all wiring is in good condition and that the wires have not pulled out of the terminals. To verify this,
look inside each connector and verify that the terminal pins are all at the same height. If a terminal is starting to
back out, it will appear to be lower in the connector, or the seal on the back-side will be protruding out farther
than the rest.
4. Unplug the EFI harness and plug original harness back into the injectors and verify that the sled runs OK.
5. If problem only occurs with Control Box plugged in, change all fuel adjustment settings to 0 and see if problem
persists.
6. Verify that the Control Box does not reset itself when the sled is running by doing the following:
a. When the sled is first powered up, change the menu screen on the Control Box to one of the fuel adjust
screens.
b. Run the sled.
c. Before shutting off the sled, verify that the screen is still on the same menu selection.
d. If the startup screen is displayed (showing version number etc.), the box has reset itself. This is likely
caused by bad voltage to the box due to an intermittent connection.
7. If necessary, the voltage supply to the box can be verified using a voltmeter. Probe from the Mag-side gray
connector on the EFI harness where two red wires go to one connector terminal. Insert a small thin wire such as a
paperclip or a small probe tip between the connector and the rubber seal in order to make contact with the terminal
inside. Place the positive voltmeter probe here. Place the negative voltmeter probe on chassis ground. At idle the
DC voltage should read around 12-14V.
Rough Idle: Idle adjustments are much more sensitive than other adjustments since the injectors are on for a
very short duration. You may not be able to adjust your 3000 LO settings by very much.
LCD is dim: If you are using a 9 volt battery to power the box when the sled is not running, your battery voltage
is getting low – replace your battery. Extreme hot or cold temperatures may cause the LCD to not
display properly.
LCD display is slow: Cold weather conditions can make the LCD respond very slowly. The Control Box will still
function OK. You can locate the box under the hood in order to provide heat so the LCD will
display quicker.
Moisture on LCD: Condensation is normal if the Control Box is quickly moved from a cold to a warm environment.
In some cases, the Control Box enclosure may no longer be sealing properly. If such problems
persist, contact Boondocker to determine if resealing the box is necessary.
Check Engine light: Make sure the wires in the EFI harness are correct and check for a bad connection in the wiring
harness. Recheck all connectors and be sure each is completely latched. Also inspect each wire to
make sure there are no frayed, broken, or melted wires. Look at the seals on the back of each
connector – if a pin has backed out, its wire seal will be protruding out of the connector more than
the rest.
Note: When using pump gas, be aware that the fuel quality can vary and has been known to be less than that shown on the
pump! We recommend you obtain fuel from a known source and/or mix with race gas if in doubt.
Limited Warranty – Boondocker warrants its product to the original purchaser against workmanship defects for a period
of 90 days, commencing from the date of product delivery to the Consumer.
Maximum Liability – The maximum liability of Boondocker in connection with this warranty shall not under any
circumstances exceed the price of the product claimed to be defective.