BD turbo tuning help...

[AndyL]

First ride today on 800 dragon and it fell flat on its face. Started with bd suggested numbers and it was WAY lean. Sled would back fire bog and die. Looked at every wire to make sure it was connected and made sure ebc was calibrated and set to zero boost.
I started to increase the psi numbers and would very slowly get better. Finally ended up at 97/127/127. 3000 rpm was 0/9/12 and 5000 rpm was 12/12/12.
The sled would rip at wide open throttle with a 12.0-12.6 a/f. Low end was still bad and the middle was still lean at 14-16 a/f. My plugs are reading super lean and decided to bag it before it melted down. I'm no sure where to go from here. I'm running straight 110 at 3000 feet and usually ride 6k but didn't make it that far. I've also tried spraying all the intake points for air leaks and it doesn't affect anything and continues to idle perfect. Any ideas???

 

[Mag]

Is this a kit you recently installed or a recently acquired sled with the turbo already on it?

 

[AndyL]

Recently installed used kit. According to the seller it ran great before he took it off.

 

[Mag]

Those numbers should have that sled slobbering all over itself, I'll look at mine tomorrow and let you know what #'s I've got for 2500'.

Take the pressure line that runs from the ebc to the "air box" or intercooler off and make sure it's not plugged or kinked, if that isnt it you've probably got an electrical issue. What flash is your ecu running?

 

[snowcowboyz]

Your numbers seem crazy rich to me?? 3000 I run 0/0/0. 5000 0/2/0. Psi 32/46/52. 100 LL fuel at 6000-9000 13.6 psi max. Mine is a boon docker kit with inter cooler ,but no ebc??? So maybe yours is different. I've run these numbers for 4 years and 2600 miles. Never had a problem. Good luck

 

[AndyL]

Thanks. Took the line off and can blow through it good. It's the latest polaris update flash. Feb 10?

 

[Vertical Asshauler]

Your numbers seem crazy rich to me?? 3000 I run 0/0/0. 5000 0/2/0. Psi 32/46/52. 100 LL fuel at 6000-9000 13.6 psi max. Mine is a boon docker kit with inter cooler ,but no ebc??? So maybe yours is different. I've run these numbers for 4 years and 2600 miles. Never had a problem. Good luck

x2 on crazy rich

Are you tuning this on a hot pipe ? Has fuel filter been replaced when the kit was installed?

 

[AndyL]

No my fuel filter is a season old, I'll get one coming. I did make sure the motor was warmed up before I started adding fuel. To get where I'm at I would ride 10' till it poped and sputter, stop, add fuel and repeat untill it would be rideable. I tried to by pass the boondocker box with the pigtail they offer but when it was plugged the motor wouldn't start. To install it you unplug one of the two wires from the bd box and put the looped harness in place of of correct?

 

[diamonddave]

Hey guys, doesn't he want to be running the 08 or 09 flash?

 

[Mag]

He should be running the early 09 flash. The sled should run with the bypass in it, there's a wiring problem somewhere.

 

[AndyL]

Started doing resistance tests on the main harness that the stock ecu plugs into. Im not getting anything on 4 wires. Green, Green/white, Yellow/white and Yellow. I dont see any breaks in the line can they be going other places other than the ecu??

 

[Mag]

BD # 877-522-7805 if you can get with one of the tech's they can help you more with the diagnostics. You may have to try back several times but they are pretty good to work with when you do get a hold of them. Unless there's somebody near you that you can get together with and go thru yours side by side bd may be the fastest way to get you fixed.

 

[wild rose shows]

If you have a electronic boost controller it needs to be calibrated to the fuel controller.Go to the stats screen on the fuel controller,the number on the top right hand corner has to be set at 0 or -0.3 .

 

[Vertical Asshauler]

Started doing resistance tests on the main harness that the stock ecu plugs into. Im not getting anything on 4 wires. Green, Green/white, Yellow/white and Yellow. I dont see any breaks in the line can they be going other places other than the ecu??

Take a close look at the pins in the control box connectors (the 2 white ones) They tend to pull out if the wires get tugged on.

 

[AndyL]

I'll look closer at those wires. I have the ebc calibrated however in real time I'm not getting 8 psi on the screen. Even though the 'set boost' is at zero shouldn't I see 8.0 on the screen at wot?

 

[Vertical Asshauler]

What numbers are you seeing on the EBC at WOT? Or is it staying at zero?

 

[turbonium]

flash

Having the correct ecu flash is very important.
Must have 09 flash for it to run...

 

[Nubulin]

You have to remember that the numbers are only relevant to another box with the same programming. If your box does not have the same map as another one, then your 0/0/0 might be thier 12/25/50. The numbers adjust up and down from thier map.

If you got it second hand, maybe have BD flash the box with the correct programming for that kit and start with thier base numbers.

 

[AndyL]

A little closure I think. Call bd and the 4 wires that didn't get a reading are signal wires. That makes the harness check out and while looking at the sleds ecu port, I noticed the rubber came off the connector and wasn't making a perfect fit. I fished out the seal and reconnected it and fired it up.
The sled started right up but if I touched the gas it died. Realizes I had the maxed out numbers and set everything to stock settings from bd. I fired it up again and it runs night and day difference!
To ease my mind I installed the by pass for the control box and the sled started no issues. I even tested it with stock ecu only and everything checks out. I'm hoping it was just a stupid rubber seal causing all this. Ill report back when I ride again. Thanks everyone, what an experience.

 

[AndyL]

Like you guys were saying, yes I do need the 09 flash.
It's #4012707 in the digital wrench using yellow injectors.