D&D HiJacker. For 2009 Arctic Cat Z1 Turbo Quick-start wiring information is in Section II.D., but be sure to read all the warnings in Section I.

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1 D&D HiJacker For 2009 Arctic Cat Z1 Turbo Quick-start wiring information is in Section II.D., but be sure to read all the warnings in Section I. Before you begin, please read all the instructions below and check kit contents. HiJacker Kit Contents: Quality check by: 1 HiJacker Control Box 1 button harness 1 battery clip 1 reusable zip-tie 1 instruction manual 2 8 Zip ties 2 male quick-connect terminals 2 female quick-connect terminals 1 T tap 1 ¼-20 x ½ hex head bolt 1 ¼-20 nylock nut 1 small piece of Velcro for button. IMPORTANT - PRODUCT REGISTRATION: Please register this product online as soon as possible (if you do not have internet access, please call us at ). It is required that you register this product so you can receive technical support, make warranty claims, and so you can keep informed of product updates. To register, go to select Contact Us then select Registration Form. Please complete the on-line form. I. Theory of Operation: The HiJacker connects between the sled s ECU (Engine 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 these signals, it is possible to make certain fuel changes while leveraging from the stock fuel map. This means the ECU can still compensate for engine speed, throttle position, barometric pressure, engine temperature, air temperature, etc. The HiJacker can increase or reduce fuel amounts at selected RPM ranges and load conditions. This serves the same function as re-jetting a carburetor. The user tunes using the buttons and LCD display. As with tuning a carburetor, it is possible to go too rich or too lean! The HiJacker also allows turbo boost to go higher than the stock level. The amount of additional boost is selected by the user through a horsepower setting. The horsepower numbers are only approximate. Each five horsepower increase adds about 0.6psi to the boost limit. However, the total amount of achievable boost is limited by the exhaust system. For example, the stock exhaust will only allow about six extra pounds of boost (about 50 extra HP). Aftermarket exhausts with mufflers will allow about seven to nine extra pounds (about 60 to 75 extra HP). A wide open short pipe will allow about ten extra pounds of boost (about 85 extra HP). Check the laws in your area regarding muffler requirements. The D&D HiJacker adds fuel for this extra boost as selected by the user. Revised Hijacker is a trademark of Boondocker Page 1 of 15

2 Revised Hijacker is a trademark of Boondocker Page 2 of 15

3 The HiJacker has several unique features in addition to EFI control, boost control, and variable horsepower setting: HiJacker control will not override Arctic Cat s designed-in boost reduction safety feature. The Rapid Response button allows instant boost buildup plus a momentary horsepower increase (+HP) while the button is pressed. The size of the +HP increase is user selectable. In addition to button control, instant boost and +HP can be triggered by engine load or by a combination of engine load and RPM. This is the Boondocker Synergy feature. IMPORTANT NOTES READ THIS! Caution 1: Be sure you know how to properly tune an engine before you adjust the fuel settings! Use of an Air/Fuel Gauge and plug readings are highly recommended when tuning. Caution 2: Engine damage will result from running low octane fuel at high boost. Do not set your horsepower higher than 210 if you are using 93 octane fuel. For higher boost use 110 octane or higher. Be sure to watch for error codes indicating low octane or detonation. If your boost drops to about 9psig, look for engine codes and warnings. Note 1: Never unplug the HiJacker 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 HiJacker 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 HiJacker is sealed do not take it apart or it will no longer be sealed. The HiJacker 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 HiJacker exposed to the elements. Note 5: Always use Resistor Spark Plugs! Non-resistor plugs WILL cause electrical interference with the HiJacker. Revised Hijacker is a trademark of Boondocker Page 3 of 15

4 II. Installation A. Removing panels Remove seat by pushing rearward and lifting the front or by removing front bracket (Figure 1). Remove the hood, left side panel, and instrument pod. The instrument pod is held with two long Torx bolts at the rear of the pod near the steering column. Remove gas tank fascia (Figure 2). Remove the lower left-side tank cover side panel (Figures 3, 4, and 5) to gain access to the intake manifold and injector harness connector. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Revised Hijacker is a trademark of Boondocker Page 4 of 15

5 B. Location of HiJacker box The best location for the HiJacker Control Box is on the panel below the handlebars and to the right of center. The box can also be mounted under the hood, anywhere on the dash or on the handlebars using the supplied Velcro strips. Check to be sure the HiJacker harness will reach from your chosen location to where it connects (preview sections C and D below). Before applying the adhesive strips, thoroughly clean each surface (rubbing alcohol works well). It will adhere best if each surface is warmed up with a hair dryer. If the box is mounted under the hood, keep the box away from excess heat, and away from the ignition coils. C. Routing harness Route the harness down along the steering column then left along the steering hoop and coming out between the steering hoop and intake manifold. D. Wiring 1) Ground Use the supplied bolt and nylock nut to attach the ring terminal to the perforated clutch vent as shown in Figure 6. Tighten bolt very securely as a bad ground will cause any of several types of malfunctions. On special edition sleds this panel is painted so it will not ground properly. In this case, use one of the steering hoop bolts in the same area. Figure 6 2) Wire Taps On the left side of the intake manifold, locate the sensor having three wires: black/blue, blue/red, and green/gray (Figure 7). Remove the sensor connector for easy access. Cut the green/gray wire 3 from the sensor connector. Slit the plastic sheath if necessary. Cut the black/blue wire 3 from the sensor connector. Strip all four wire ends 3/8. Figure 7 On the connector side of the cuts, crimp a female connector on the green/gray wire and a male connector on the black/blue wire. On the harness side of the cuts, crimp a male connector on the green/gray wire and a female connector on the black/blue wire. Pull on each of these four terminals to be sure the crimps are solid. If the wire wiggles in the connection, it will be intermittent. Only after pull testing, use heat to shrink the sleeve on each of these four terminals. See the terminals on the HiJacker for an example of how they will look when completed. Plug the HiJacker s green/white wire into the green/gray wire on the connector side. Plug the HiJacker s gray/white wire into the green/gray wire on the harness side. Plug the HiJacker black blue wire into both of the black/blue wires on the sled. To restore your sled to stock configuration, disconnect the HiJacker wires and plug the stock wires together while matching colors. Revised Hijacker is a trademark of Boondocker Page 5 of 15

6 Inside the engine area and near the left side, locate the solenoid having a red/green wire and a black or black/brown wire (Figures 8 and 9). Note that there are two solenoids in this area having nearly identical wire colors. Use the solenoid toward the front of the sled, having one hose going to the charge tube and another going to the turbo. Route the HiJacker s purple/white wire to this area. Keep it away from the moving parts and hot areas. Slice the sheath of the solenoid harness to gain access to the black or black/brown wire. Note where the purple/white wire will reach and install T-tap in this location. Tape sheath together around T-tap to eliminate bending and vibration. Plug purple/white wire into T-tap. Figure 8 Figure 9 3) EFI connector Locate and disconnect the sled s EFI connector (Figure 10). It is located under the intake manifold and coils. Plug each connector into the HiJacker connectors. To restore your sled to stock configuration, disconnect the HiJacker connectors and plug the stock connectors back together. Figure 10 4) Button (optional) Zip tie the button to the left handlebar and route the wire down along the steering column. Plug it into the connector that comes out of the harness sleeve about 10 from the HiJacker box. The white wire at this location is unused. 5) Wire dressing Use zip ties to secure the wires and harnesses away from hot or moving parts and to prevent wire vibration, bending, catching, etc. Note: If these instructions have been followed exactly, then all HiJacker connections can be unplugged and the sled can be plugged back into stock configuration for troubleshooting. Revised Hijacker is a trademark of Boondocker Page 6 of 15

7 III. Battery Clip When the engine is off, the HiJacker has no power. For learning and tuning purposes, D&D has provided a battery clip that can be used to power the HiJacker. Unplug the button and plug in this 9V battery clip when power is needed. Note: Do not leave the battery plugged in while the engine is running. Do not leave battery plugged in when not using it. IV. HiJacker Operation A. Intro / Startup Screen When the box is first turned on (by the engine or battery), the Intro screen is displayed. Press any key to go to the main menu. An example Intro screen display is shown below: D&D HiJacker 7C1I02 HP:180 In the example shown above, this screen displays the following information: D&D HiJacker 7C1I02 HP:180 Product name. The HiJacker is only for the 2009 Arctic Cat Z1 Turbo. This is the program version in the box. The box can be reprogrammed only by bringing or sending the box back to D&D. Shows the current horsepower setting. B. Main Menu The Main Menu is shown below: MAIN Fuel Stats MENU Set Hp180 For all menus, the current selection is shown by the arrow ( ) and the cursor (underscore below the F ). Use the arrow keys on the keypad to move the cursor. Move the cursor to the desired selection and press the SEL key to select the desired menu option. From the main menu, choose from the following: Fuel Go to the Fuel adjust menus (see Section 1 below). Stats Display runtime data, captured data, and recorded maximum data (see Section 4 below). Set Set up options for the button function and Synergy configuration (see Section 3 below). Hp180 Go to the Horsepower menu (see Section 2 below) Revised Hijacker is a trademark of Boondocker Page 7 of 15

8 1. Fuel Adjust Menus This selection is used to make fuel adjustments. There are three Fuel adjust screens (examples shown below). The first screen comes up after selecting Fuel. Fuel screen1: M1U Id MD HI Fuel screen2: PSI screen: M1U LO MD HI M1U LO MD HI Psi Use the Up/Down Arrow keys to change the settings. Use the Left/Right Arrow keys to switch between the LO/MD/HI settings. Go to the next adjustment screen by pressing the SEL button. After pressing the SEL on the last Fuel adjust screen, you will return to the Main Menu. RPM-based Fuel Adjustments M1U Unused in the HiJacker. M1U Id MD HI This is the RPM Region for the fuel adjustments on this screen. For this example, this screen s adjustments will be centered at 3000rpm. Id LO MD HI (3000 screen only) This adjustment is for Idle only (up to 2000rpm). This adjustment is for Low engine load conditions. This will affect throttle settings from approximately 0 up to 1/3. This setting will affect deceleration and light-load cruising conditions. This adjustment is for Medium (mid-range) load conditions. This will affect throttle settings from approximately 1/3 up to 2/3. This adjustment is for High load conditions. This will affect throttle settings from approximately 2/3 to full open. Fuel adjustments between two RPM ranges are a proportionate blend of the settings above and below it. For example, since 4000RPM is exactly mid way between 3000 and 5000 RPM, the fuel adjustment at 4000RPM will be exactly mid way between the 3000RPM fuel number and the 5000RPM fuel number. This allows for a broader range of adjustments with fewer steps. The setting for all RPMs below 3000RPM is the same as the value for 3000RPM. To adjust fuel at an RPM that is between screen values, use the fuel screen with the closest RPM. Boost Pressure Fuel Adjustments M1U LO MD HI Psi Extra boost fuel is added by the HiJacker. The higher the boost pressure, the more fuel that is automatically added. The user-adjustable number in the menu represents how much fuel is added for each additional pound of boost. As in the RPM fuel screen, LO, MD, and HI still represent engine load or throttle position. Note: Depending upon your modifications, it may be possible to max out the injector (duty cycle > 100%). Pay careful attention to EGT s, O2 readings, and fuel pressure when running with engine mods that allow over 16psi boost! Revised Hijacker is a trademark of Boondocker Page 8 of 15

9 2. Horsepower Menu Select Power 180 BtnAdd: 10 This selection is used to adjust your peak horsepower and set a value for an extra horsepower punch (+HP). This extra horsepower can be triggered with the button or with Synergy. Synergy uses injector duty cycle or duty cycle and RPM information to trigger this extra horsepower. Synergy can be used with or without the button. Note: Don t set your horsepower plus the BtnAdd (+HP) amount to a value higher than your fuel octane will support. Pay careful attention to the Z1 s octane warning and detonation codes. Also, octane problems can cause the sled to default to a maximum of 9psi boost. To help protect your engine, the HiJacker deliberately does not override this safety feature. 3. Setup Menus Fuel DCy RPM Btn 002 OFF OFF +HP From the Main Menu, select Set to go to the Setup Menu (shown above). This screen is used to set a fuel amount for tuning experiments, Synergy settings (DCy and RPM), and the button function. See Section VI for a summary of Synergy and Rapid Response. 3.1 Fuel This sets the fuel amount that is added or subtracted in small amounts to experiment with tuning changes when the button mode is set on TUN (see below for button modes). Set this to zero if the button or Synergy will be used to activate a wet nitrous system. 3.2 DCy and RPM These are for Synergy configuration. If you select DCy, the following menu appears: DCy N2O on if OFF DCy > 50 If you turn DCy (duty cycle) on, then Synergy will activate either Rapid Response or nitrous, depending upon how your button and sled are configured. Set the duty cycle number above which you want Synergy to activate. Duty cycle triggering can work either with or without RPM triggering. If you select RPM, the following menu appears: RPM Min Max OFF If you turn RPM on, then Synergy will activate either Rapid Response or nitrous, depending upon how your button and sled are configured. For Synergy to work with RPM, DCy must also be turned on. Set the RPM range where you want the Synergy to activate. Synergy will only activate between the two RPM values. 3.3 Button modes 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: +HP: N2O: Description: Btn Increase HP: +HP When the button is pressed or when Synergy is activated, the extra horsepower punch selected in the horsepower menu will be added plus boost will come on more quickly (Rapid Response). Description: Btn N2O + Fuel : N2O Do not leave the button in this mode unless your sled is configured for a wet nitrous system. Contact Boondocker for nitrous configuration details. Revised Hijacker is a trademark of Boondocker Page 9 of 15

10 TUN: CAP: ARM: Description: Btn Fuel only : TUN When the handlebar button is pressed in TUN mode, fuel is added or subtracted in the amount shown under Fuel in the Set menu. This feature is used to experiment with fuel addition and subtraction while riding. Press the button at a certain rpm or under a certain load to see whether your addition or subtraction is beneficial. This cannot be used in combination with Rapid Response. Be sure DCy and RPM triggering are OFF when using this feature. Also, be sure to set the fuel value to a very low number like one or two. Description: Btn StatCapture: CAP In CAP mode, the handlebar button is used to capture current data. When pressed, the Stats Capture screen will be displayed. The data will be frozen when the button is released. After a capture, pressing the Right-Arrow button will erase the captured data and return to Run Mode. This feature can be used to locate trouble spots to aid in tuning. Description: Btn On for N2O : ARM By using a pushbutton (momentary), toggle, rocker, or slide switch connected to the button input, Synergy can be armed or disarmed. When the switch is closed the system is armed and ready for Synergy activation of Rapid Response. When the switch is open, the system is disarmed so neither DCy nor RPM will result in Synergy activation. See Section VI for more details. Rapid Response activation idea: One way to use the button for Rapid Response activation and to have the RPM limiting feature (to prevent hitting the rev-limiter): set Btn to ARM, DCy 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 Set menu or push the SEL button to return to the Main Menu. 4. Stats Menus The HiJacker has a feature that allows real-time data to be displayed and captured. This feature can be useful for tuning or for diagnostic purposes. 4.1 Stats: RUN/CAPTURE Selecting Stats from the Main Menu will first display the following screen with real Run-time data (current conditions): Run 65/ MD 14 Run Run indicates display is in Run mode. If in capture mode, Cap will be displayed. 65 Input duty cycle from ECU in percent 74 Output duty cycle to injector in percent 12.2 Boost pressure (psig) 6500 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 14 Percentage of fuel added for extra boost Revised Hijacker is a trademark of Boondocker Page 10 of 15

11 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 Left-Arrow 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 HiJacker 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. Also, when the handlebar button is configured for capture mode, this is the screen that appears when the button is released. Right-Arrow button : Clears capture mode (captured data will be lost!) and sets to Run mode. Run will be displayed and real-time data will be displayed. Press SEL to go to the next screen: Stats: MAX. 4.2 Stats: MAX Pressing SEL, Up-Arrow, or Down-Arrow from the Run screen will go to the next Stats screen which is the Max screen, displaying max RPM, Duty Cycle In from the sled s ECU, and Duty Cycle Out to the injectors. MAX DCIn/Out Clr /83 Y N MAX: 7620 Max RPM DCIn 65 Max Duty Cycle Input from sled s ECU. DCOut 83 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 timewindow. 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: PSI MAX/Peak. 4.3 Stats: PSI MAX/Peak This menu displays max and peak boost pressure. PSI MAX Peak Clr Y N MAX 13.2 Maximum boost( in psig) averaged over about one second. Peak 14.7 Peak boost (in psig) without averaging. 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 main menu. Revised Hijacker is a trademark of Boondocker Page 11 of 15

12 V. EFI Tuning Suggestions The HiJacker requires very little tuning, if any. Yet due to variations in sleds and conditions, its default settings cannot be guaranteed to be correct. To tune your sled, it is highly recommended that you use an air/fuel gauge, an EGT gauge, and read the plugs. The HiJacker will not prevent a lean burndown! You must take the proper tuning steps the same as if you were tuning a carburetor. Positive RPM fuel numbers add fuel and negative numbers subtract fuel. Be extremely careful with negative numbers. Never use negative numbers for the PSI setting. Even though the setting numbers can go quite high, this does not mean you have an effective range that large. At some point the injector will be at 100% duty cycle (always open) and no more fuel can be added. 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, boost, and can be different from sled to sled even of the same model. 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. 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 crank awhile with the throttle held wide open. 3. To help isolate a problem spot, the Stats Capture feature can be used to determine RPM, and whether the load setting is LO, MD, or HI. The button can be configured to capture these stats. From the Main Menu, select Set, 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. Setup Menu in Capture mode: Fuel TPS RPM Btn 002 OFF OFF CAP 4. The handlebar button can be used to add or subtract a preset amount of fuel for interactive tuning purposes. From the Main Menu, select Set, 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 button is pressed, this amount of fuel will be added or subtracted immediately from the current settings for all RPMs and all loads. Setup Menu in TUNE mode: Fuel TPS RPM Btn 002 OFF OFF TUN Revised Hijacker is a trademark of Boondocker Page 12 of 15

13 Also consider the following: A/F Mixture Generally EGT s get hotter as the motor gets lean, but too lean and the temperatures 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 Timing Fuel Lean spots 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. The Z1 has a detonation sensor. Watch for and pay close attention to error codes. 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. Different fuels have different densities and other characteristics which can affect mixture and fuel requirements. Oxygenated fuel will run leaner. Octane rating is important for turbos, and especially when the HP setting is turned up from stock. 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 erratically. 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. Revised Hijacker is a trademark of Boondocker Page 13 of 15

14 VI. Synergy and Rapid Response Configuration There are seven ways to configure Rapid Response activation using one or more of the following inputs: button, engine load (throttle position), and RPM range. This configuration is made from the setup (Set) menu. A brief description for each configuration is given below. 1. Button only: In the Setup Menu, turn RPM and DCy on and set Btn to +HP. Pressing the momentary button activates Rapid Response and adds extra horsepower (+HP) according to the BtnAdd amount. Releasing the button turns it off and horsepower returns to the base value set in the HP menu. The button activates Rapid Response and +HP regardless of engine load or RPM conditions. 2. Duty Cycle (engine load) only: Turn DCy on and turn RPM off. The throttle determines engine load and engine load directly affects injector duty cycle. When the duty cycle is over a point set by the user, Rapid Response and +HP are activated. They are deactivated when the duty cycle returns to a point below the chosen threshold (throttle is reduced). You do not need to press the button. Optionally, deactivate the button by setting its mode to CAP. 3. Duty Cycle and RPM: Turn on DCy and RPM. When the RPM and duty cycle are within the range set by the user, Rapid Response and +HP will activate. It will turn off when the duty cycle is decreased or when the RPM is outside of the selected range (lower than Min or higher than Max). You do not need to press the button. Optionally, deactivate the button by setting its mode to CAP. 4. Button (+HP) or Duty Cycle: Turn DCy on, turn RPM off, and set Btn to +HP. The handlebar button can be used in combination with duty cycle. In this way, either engine load or the button can activate Rapid Response and +HP. In the +HP mode, the button will activate Rapid Response and +HP regardless of duty cycle. Duty cycle will activate Rapid Response and +HP regardless of whether the button is pressed. 5. Button (+HP) or Duty Cycle and RPM: Turn DCy and RPM on and set Btn to +HP. The handlebar button can be used in combination with duty cycle and RPM range. In this way, either the button or duty cycle/rpm can activate Rapid Response and +HP. In the +HP mode, the button will activate Rapid Response and +HP regardless of duty cycle and RPM. Duty cycle and RPM will activate Rapid Response and +HP regardless of whether the button is pressed. 6. Button (ARM) with Duty Cycle: The button input on the HiJacker can be used to quickly arm and disarm Rapid Response/+HP capability. Set Btn to ARM, DCy to ON, and RPM to OFF. When the button is on, the system is armed and can be activated by duty cycle alone. 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. 7. Button (ARM) with Duty Cycle and RPM: Same as option 6 above except set RPM to ON. When armed (button input is on), the system can be configured to activate when duty cycle and RPM are within set limits. Revised Hijacker is a trademark of Boondocker Page 14 of 15

15 VII. HiJacker Troubleshooting Note: A common problem is a bad ground connection. The first step in troubleshooting is to be sure that the HiJacker ground and ECU ground connections (behind and below battery) are solid. Symptoms and Issues Engine runs erratically or doesn t run at all: 1. Verify that the HiJacker ground wire is solidly bolted at the perforated clutch vent. 2. Verify that the ground on the sled s harness has a good connection to the chassis. (behind and below battery). 3. Check all terminal connections and crimps. Be sure fuel injector connectors are fully seated. 4. Verify that all wiring is in good condition, not melted or rubbed through, and that the fuel injector connector terminals are seated in the connector housings. 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. 5. Unplug the HiJacker connectors and plug in the sled s wires to restore it to stock condition. Verify that the sled runs OK. If not, it could be a problem with the sled itself or a problem with the crimped terminals. 6. If problem only occurs with HiJacker plugged in, change all RPM fuel adjustment settings to 0 and see if problem persists. Do not change PSI fuel settings. 7. Verify that the HiJacker 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 HiJacker 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 power or ground connections to the box due to an intermittent connection. Rough Idle: LCD is dim: Idle adjustments are much more sensitive than other adjustments since the injectors are on for a very short duration. In the Fuel menus, change the 3000 ID setting. 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 HiJacker will still function OK. Moisture on LCD: Condensation is normal if the HiJacker is quickly moved from a cold to a warm environment. VIII. Warranty, Terms & Conditions Returned Goods No merchandise will be accepted without prior approval. A RMA number (Return Merchandise Authorization) provided by Boondocker is required before a return will be accepted. A 20% handling and restocking charge will be applied to returned merchandise. No unauthorized returns will be accepted. 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. Revised Hijacker is a trademark of Boondocker Page 15 of 15