Boston Whaler 160 Dauntless Owner's manual

Brand: Boston Whaler

Model: 160 Dauntless

Type: Owner's manual

INFORMATION IN THIS PUBLICATION IS BASED ON THE LATEST PRODUCT SPECIFICATIONS AVAILABLE AT PRINTING, BOSTON WHALER® BOATS, INC. RESERVES THE RIGHT

TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE, IN THE COLORS, EQUIPMENT, SPECIFICATIONS, MATERIALS AND PRICES OF ALL MODELS, OR TO DISCONTINUE MODELS.

SHOULD CHANGES OR MODIFICATIONS TO THE MODELS BE MADE BOSTON WHALER® IS NOT OBLIGATED TO MAKE SIMILAR CHANGES OR MODIFICATIONS TO MODELS

SOLD PRIOR TO THE DATE OF SUCH CHANGES. THE FOLLOWING ARE REGISTERED TRADEMARKS OF THE BRUNSWICK CORPORATION:

160 DAUNTLESS, BOSTON WHALER

. MRP #1808097

The mission of Boston Whaler® is

to provide consumers with the

safest, highest quality, most durable

boats in the world

Rev E 10/11/05

Boston Whaler founder

Richard T. Fisher demon-

strating one of the fea-

tures that has made Bos-

ton Whaler the Unsink-

able Legend in this

1961 LIFE Magazine

Photo.

Richard T. Fisher was

posthumously inducted

into the National Marine

Manufacturers Associa-

tion (NMMA) Hall of

Fame on September 26,

1996 for accomplish-

ments made in marine

engineering and con-

struction.

History

In 1958, company founder Richard T. Fisher introduced the first Boston Whaler boat in Braintree,

Massachussetts. It featured two significant innovations: first, its twin sponson hull design produced superior

stability and a remarkably dry ride; second, its unique foam core construction made the boat not only du-

rable, but unsinkable as well.

Fisher took every opportunity to illustrate the unique characteristics of the Boston Whaler. His most famous

demonstration was captured in 1961, by Life Magazine. The series of photographs showed the boat under-

way, the boat being sawed in half and ultimately Fisher motoring away in the remaining half of the boat. And

through the years many other demonstrations have proved the toughness and durability of the Boston Whaler

hull. And though you may never cut your boat in half, this only goes to show one thing, people whose

livelihood and lives depend on boats consistently choose Boston Whaler because of their seaworthiness,

dependablility and the inherent safety of a hull that wont sink even if severely damaged.

Boston Whalers are built to last. For over 40 years Boston Whaler® has strived to make each model better,

providing you with a safe and fun boating experience. That is the reason we offer a 10 year limited transfer-

able warranty. It is also an excellent reason why you can trust the safety of your family and friends to a

Boston Whaler.

PLEASE KEEP THIS OWNERS MANUAL PACKET IN A SECURE PLACE, AND BE SURE TO HAND IT

OVER TO THE NEW OWNER IF YOU SELL THE BOAT.

Section 1 - 160 Dauntless

Table of Contents

Section 5-Bilge System

Bilge Pump 16

Operation 16

Maintenance 16

Livewell, (optional) 16

Operation 16

Maintenance 16

Section 6-Propulsion System

Propeller Information 17

Propeller Assembly 17

Gear Shift/Throttle Control 18

Power Trim Operation 18

Steering Information 19

Operation/Maintenance 19

Steering Pull 19

Section 7-Getting to know your Boston Whaler

Mooring Points 20

Lifting 20

Hull Maintenance 21

Hull Maintenance, (Blisters) 21

Bottom Painting 22

Painted Hull Care, (Bottom) 22

Vinyl Cushion Care 22

Long Term Storage 23

Engine 23

Fuel System 23

Electrical System 23

Drainage 23

Canvas Care & Maintenance 23

Trailer (Optional) 24

Section 8-Anchoring Information

Anchoring Information 25

Lowering 25

Setting 25

Weighing 25

Section 9-Maintenance Log & Notes

Maintenance Log & Notes 26

160 Dauntless - Owners Manual

Section 1-160 Dauntless

Introduction 1

Table of Contents 1

Construction Standards 2

Our Hull 2

Servicing your Boston Whaler 2

Hull Identification Number 2

Section 2-General Arrangements

& Specifications

Specifications & Dimensions 3

Standard Features 4

Optional Features 5

Standard Seating 5

Optional Seating 5

Canvas Arrangement 6

Through-Hull Fittings 6

Label Locations 7

Deck Occupancy 7

Trolling Motor 8

Section 3-Fuel System

Fuel System 9

Fuel Fill 9

Fuel System Diagram 9

Fuel Vent 9

Empty Tank 10

Hoses & Fittings 10

Tank Cleaning 10

Static Electricity and the Fuel System 10

Section 4-Electrical System

Electrical System 11

Battery Information 11

Battery Maintenance 11

Battery Options 11

Electrical Schematic 12

Instrument Panels 13

Multi-System Tachometer Display 14

Multi-System Speedometer Display 14

Battery Switch, (optional) 15

Ignition Shutdown Switch 15

Navigation Lighting 15

Operation 15

This Owners Manual has been written to provide specific information about your boat and it should be read carefully.

Keep this booklet with the Owners Manual in the Owners Manual Packet.

The Owners Manual Packet has been compiled to help you operate your boat with safety and pleasure. It contains

details of the boat, the equipment supplied or fitted, its systems and information on its operation and maintenance.

Please familiarize yourself with the boat and its operation before using it.

If this is your first boat, or you are changing to a type of boat you are not familiar with, for your own comfort and

safety, please ensure that you obtain handling and operating experience before assuming command of your boat.

Your Boston Whaler® dealer or local Yacht Club will be pleased to advise you of marine safety classes and safe

boating classes in your area.

Introduction

Section 1 - 160 Dauntless

160 Dauntless - Owners Manual

Hull

Identification

Number

THE MISSION OF BOSTON WHALER IS TO PROVIDE CONSUMERS WITH THE

SAFEST, HIGHEST QUALITY, MOST DURABLE BOATS IN THE WORLD.

We are dedicated to creating a superior product providing you with comfort, performance, safety and dependability.

All of our boats comply with the safety standards set by the United States Coast Guard and are designed, engineered

and manufactured in accordance with applicable recommendations and guidelines of the American Boat and Yacht

Council (A.B.Y.C.) and certified by the National Marine Manufacturers Association (N.M.M.A.).

Construction Standards

Hull Identifcation Number

The Hull Identification Number is located on the

starboard side of the transom wall.

This is the most important identifying factor and must

be included in all correspondence related to your ves-

sel. Failure to do so will only create delays. Also of

vital importance are the engine serial numbers and

part numbers when writing about or ordering parts

for your engine.

Our Hull

Boston Whaler® hulls are constructed with our pat-

ented Unibond construction. This involves shoot-

ing high density foam into a closed mold system.

The foam expands to fill voids in the hull, and when

the finished product is pulled from the mold, the deck

and the hull are chemically bonded to form a solid,

inseparable unit.

1 No air voids

2 High density closed cell non-absorbent foam

3 High quality resins and gelcoats

4 Woven glass matting

When your 160 Dauntless needs to be serviced or

regular maintenance is needed, it should be taken to

an authorized Boston Whaler® dealer.

To find a Boston Whaler® dealer in your area call:

1-800-942-5379

Domestic/International

If a problem is not handled to your satisfaction:

Discuss any warranty related problems directly

with the service manager of the dealership or your

sales person. Give the dealership an opportunity

to help the service department resolve the matter

for you.

Servicing your Boston Whaler

Typical H.I.N. Description

Section 2 - General Arrangement & Specifications

160 Dauntless - Owners Manual

163

71

49

11

71

Note: The canvas top shown here is

for reference purposes only.

***

199

Overall Length 163 4.95 m

Trailerable Length 199 6.02 m

Bridge Clearance 7 1 2.16 m

Bridge Clearance (no top)49 1.44 m

Beam 71 2.16 m

Draft, (Hull Only) 11 .27 m

Weight (dry, no engine) 1500 lbs. 680 kg

Swamped Capacity 4200 lbs 1905 kg

Maximum Engine Weight 410 lbs 185 kg

Maximum Weight, (passengers, engine-

gear) ** 1700 lbs 771 kg

Persons 6

Maximum Horsepower 115HP 85 kw

Minimum Horsepower 50 HP 37 kw

Fuel Capacity 45 gal.(U.S.) 170 L

* Waterline

*** Engine Draft,(See Notice)

Specifications & Dimensions

Specified measurements are approximations and are

subject to variance.

NOTICE

Optional equipment and loading of the boat will af-

fect the draft measurements. Follow the recommen-

dations listed on your capacity plate regarding the

maximum amount of weight the boat can safely

carry.

***

Exceeding this weight will affect the boats perfor-

mance. DO NOT Exceed the weights listed on the

capacity plate.

NOTICE

160 Dauntless - Owners Manual

Section 2 - General Arrangement & Specifications4

1 Bow Navigation Light

2 Heavy duty rubrail

3 6 Cleats, (2 bow, 2 stern)

4 Trolling motor flat

5 Anchor Locker w/ Drain & Lifting Eye

6 Compass

7 Stainless steel console grab rail

8 Instrument panel

9 Gear shift/Throttle control

10 Stainless steel steering wheel

11 Reversible pilot seat w/ locking backrest and

storage

12 Self bailing cockpit

13 Aft cockpit cupholders, (2)

14 Port aft quarter seat, storage under

15 360° Navigation/Anchor Light

16 Fuel fill

17 Motorwell Drain, (2)

18 Motorwell access hatch

19 90 ELPT EFI 4-Stroke Mercury engine

w/Stainless Steel Propeller

20 Telescoping ladder

21 Starboard aft quarter seat, storage under

22 Console cupholders, (2)

23 Fire extinguisher pocket

24 Battery/Interior console access door

25 Acrylic windshield

123

678

101112

131415

160 Dauntless

Standard Features

160 Dauntless - Owners Manual

Section 2 - General Arrangement & Specifications 5

14 Livewell fill from raw-water pump

15 500 GPH raw-water pump

16 Pump filter

17 Marelon strainer

18 115 ELPT EFI 4-Stroke Mercury Engine

19 115 ELPT OptiMax Mercury Engine

1 Sun lounge

2 Fishing seat, (2)

3 Ski pylon

4 Trolling motor panel

5 Anchor roller

6 54 Qt. (51.1L)cooler seat w/ cushion & backrest

7 Livewell in pilot seat, (see detail)

8 Red or Blue graphics

9 Tackle box

10 Console mounted rodholders, (4)

11 Livewell bucket

12 Splash guard

13 Livewell drain hose

160 Dauntless Optional

Features

Livewell detail,

backrest and cushion

removed for clarity.

To reversible pilot seat

livewell, fill

160 Dauntless Standard Seating

160 Dauntless

Optional Seating

1 Reversible pilot seat

2 Port & Starboard aft quarter seats

with removable cushions

3 54 Qt.(51.1L) cooler seat w/ cushion and

backrest.

4 Bow cushion

5 Sun lounge/Cushion

6 Removable fishing seats, (2)

160 Dauntless - Owners Manual

Section 2 - General Arrangement & Specifications6

Through-Hull Fittings

1 Livewell pump inlet, (optional)

2 Anchor locker drain

3 Aft cockpit drain, Port & starboard

4 Bilge pump outlet

5 Motorwell drain, (2)

6 Livewell drain, (optional)

7 Garboard drain

The deck drain provides self-bailing capabilities while

the boat is static in the water and no passengers on

board. This feature prevents the accumulation of wa-

ter in the cockpit. the drain must be in place when un-

derway.

NOTICE

Depending on the type of boat you have, you may

have underwater fittings that need drain plugs.

Garboard drain plugs and fishbox drain plugs need

to be in place before the boat goes into the water.

Any fitting that will be underwater needs to be

plugged or the seacock needs to be closed

NOTICE

An inspection of the through hull fittings is recom-

mended. Through hull fittings should be checked

for proper seal annually and repaired as required.

When the boat is in the water the underwater fit-

tings can be checked for dripping. It is recom-

mended that the underwater fittings be removed,

cleaned and resealed every other year.

NOTICE

If the through hull fittings need to be replaced, it is

recommended that an authorized Boston Whaler ®

dealer perform this type of repair. Through hull fit-

tings that are improperly installed can cause pre-

mature hull failure and may void the Boston

Whaler® limited warranty.

NOTICE

Detail B

1 Stainless steel aft support pole

2 Stainless steel center support pole

3 Stainless steel forward support pole

4 Aft support base

5 Aft support base locking pin

6 Center support strap, adjustable

7 Canvas boot, (Blue or Black)

8 Reversible pilot seat cover, (Blue or Black)

160 Dauntless Canvas Arrangement

See Detail

A

See Detail

B

Detail

A

160 Dauntless - Owners Manual

Section 2 - General Arrangement & Specifications 7

Accommodation deck:

This area of the boat is inside the cockpit and includes

helm seating. Movement in this area should be done with

extreme caution while the boat is underway. A sudden shift in boat

direction can cause a loss of balance and lead to injury or death.

Working deck:

This area is intended for occupation ONLY while moor-

ing, anchoring, loading/unloading or when the boat is at

rest. NEVER operate the engine while loading or unloading swim-

mers/divers from the swim platform/ladder.

Be aware of your footing while the boat is underway,

slipping or falling could result in serious injury or death,

especially if the boat is in motion or in rough water.

Keep the accommodation deck clean, so if movement

is neccessary it will be free of obstruction.

DANGER

Gelcoat surfaces are slippery when wet.Use ex-

treme caution when walking on wet surfaces. Use

care when waxing to ensure that walkways are not

made dangerously slippery.

WARNING

Never occupy the working decks while the boat is

underway. ONLY sit in areas that are designated

for sitting. NEVER sit on the gunwales (vertical

sidewalls), while the boat is moving.

WARNING

If your labels become worn or unreadable contact

your nearest Boston Whaler® dealer for replace-

ment labels. The part numbers are provided above.

NOTICE

Label Locations

1 Fuel hazard warning

2 Caution fishing ped seat position (Optional)

3 Vent hose - do not drill

4 Prop 65 hang tag

5 NMMA Certification (CE-Intl) (Canadian)

6 Maximum engine weight

7 Hi-Perf boat safety

8 Fuel gauge read warning

9 CO Warning, Helm

10 Ski pylon caution (Optional)

11 Mercury Smartcraft Networked (Optional)

12 Fuel tank caution

13 Terminal block warning

14 Do not pull rigging tag

15 CO Danger, Transom

160 Dauntless - Owners Manual

Section 2 - General Arrangement & Specifications8

Trolling Motor

The 160 Dauntless can be equipped with an optional

trolling motor panel and wiring. This option is part

of the fishing package. It consists of:

 Trolling Motor Panel

 Spare Battery Box, (located in the console).

 Reinforced Deck, (port side of the bow).

There are a variety of trolling motors and mounts

that can be fitted to your boat. See your Boston

Whaler®dealer or talk to a reputable trolling motor

dealer for the right type and size of trolling motor

and battery that will work best with your boat. There

is a section of the port bow that has-

been reinforced with Phenolic to allow for securing

the trolling motor base. The phenolic material can

be drilled and tapped to hold machine screws. When

looking for a trolling motor you will need to know

the distance from the top of the deck to the water-

line, (see Detail A). There is a spare battery box that

has been secured in the console interior and can be

accessed through the door on the port side. The wir-

ing from the panel to the battery has been routed al-

ready, (final connections can be made by a qualified

marine electrician or your Boston Whaler® dealer).

There is a risk of electrical shock. Always have a qualified ma-

rine electrician install any system upgrades that are not al-

ready installed on your boat. There are a variety of wiring con-

figurations up to 36Volts. Incorrect wiring will adversly affect

your trolling motors performance. Always use the correct cir-

cuit protection and wire gauge when installing an upgraded

trolling motor wiring system.

WARNING

Trolling Motor

Panel

Power

Cord

12 V

Accessory

Receptacle

(Detail A)

NOTICE: Refer to the TROLL-

ING MOTOR OWNERS MANUAL for

the correct size and type of bat-

tery.

Trolling Motor Phenolic

Location,

(Port Bow)

Distance from deck to waterline,

(for determining correct shaft

length).

Trolling Motor

Electrical Diagram

160 Dauntless - Owners Manual

Section 3 - Fuel System 9

1 5/8 fuel vent

2 1-1/2 fuel fill

3 45 Gal.(170 L) polyethylene fuel tank.

4 Fuel supply line to engine.

Fuel System

The 160 Dauntless is equipped with a

gasoline fuel system. Please take time

to read and understand all the fuel re-

lated information and warnings in the

engine owners packet. The diagrams

below show the location of the fuel fill, routing of

fuel supply hose and the location of the fuel tank

vent.

Fuel Fill

The 160 Dauntless fuel fill is located in the port side

of the motorwell, it is marked GAS, and is opened

by a special key that is included in the owners manual

packet.

Follow the engine manufacturers recommendation

for the types of fuel and oil to use.

CAUTION

Leaking fuel is a fire and explosion hazard, inspect

the system regularly. Examine fuel tanks, filters, and

exposed lines for leaks and corrosion.

DANGER

Check for leaks in tubing, connections and hoses.

Correct the cause of the leaks and ventilate the area

to insure that no fumes remain, prior to energizing any

electrical equipment and/or starting the engines.

CAUTION

Use of improper gasolines can damage your engine

seriously. Engine damage resulting from use of im-

proper gasoline is considered misuse of engine and

will void the warranty.

Follow engine manufacturers reccomendations re-

garding the types of fuel and oil to use.

160 Dauntless fuel system diagram

CAUTION

Oil and fuel spills can be dangerous and can subject

offenders to severe penalties

Fuel fill

Fuel Vent

The fuel tank has a fuel tank vent located amidship,

7-9 inches below the rub rail. The fuel tank vent

serves as a pressure/vacuum release, safety overflow

and flame arrestor. Access to the vent fittings is

through twist-out plate located inside the cockpit

opposite the fuel tank vent. Check the vent assembly

regularily as part of a maintenance schedule for con-

tinued safe operation of your boats fuel system. The

Vent assembly consists of a backshell, starwasher,nut

and hose clamp. Remove the hose clamp, nut,

starwasher and backshell and push the fuel vent fit-

ting out. The fuel vent has four screens that are held

in by a ring. Use a small pick to dislodge the ring to

remove the screens and clean as required.

Hull

mounted

fuel vent

with screen

160 Dauntless - Owners Manual

Section 3 - Fuel System10

EMPTY TANK:

A fuel tank with levels less than 1/4 full can cause

problems by stalling an engine due to fuel starvation

or by allowing sediment and dirt to enter the fuel

supply lines. Keeping the tank filled will reduce the

chance of this occurance; since the residue will most

likely settle to the bottom of the tank. Monitor the

fuel level often to prevent this from happening.

HOSES AND FITTINGS:

Hoses and fittings should be inspected at least every

100 hours. Check the hoses for cracks, abrasions and

deterioration and the strong smell of fuel prior to

starting the engine(s). If the hoses or fittings are dam-

aged or worn, replace them with only marine grade

replacement parts. Your authorized Boston Whaler®

dealer will have all the parts information you will

need.

TANK CLEANING:

Excessive water and sediment may force you to con-

sider having the tank professionally cleaned. If you

are frequently changing fuel filter/water seperators

and notice a loss in power, consult a professional

tank cleaning contractor regarding this procedure and

proper disposal of residue and water.

There is a danger that static electricity can ignite gaso-

line vapors that have not been ventilated outside an

enclosed area. Use extreme caution when fueling

your boat from a source outside the regular venues,

(e.g. marinas, fuel service stations.)

Your boat has safety features that can be circum-

vented by not adhering to standard fueling practices.

Your boats bonding system protects it from creating

and discharging static electricity.

Your boat must be in contact with the water or a land

based grounding system. Here are some helpful sug-

gestions to keep you safe from static electricity while

refueling your boat.

 NEVER fuel your boat in unsafe conditions such

as: suspended on a sling or in a situation that in-

creases the likelihood of static discharge.

Static Electricity and the Fuel System

 NEVER use homemade containers to fill your fuel

tanks.

 Fuel carried on-board outside of a fixed fuel sys-

tem should be stored in an approved container or

in a portable tank such as provided for outboard

engines and be stowed safely outside of the engine

or living compartment(s).

 Shut down the engine(s), motors and fans prior to

taking on fuel. Any ignition sources should be ex-

tinguished before filling the fuel tank(s).

 Close all ports, windows, doors and hatches.

 Fueling should never be done at night except in

well-lighted areas.

 Always keep the fuel nozzle in contact with the

fuel fill plate or the edge of the fuel tank opening

throughout the filling process.

 Allow areas where gasoline vapors could collect

to be ventilated before starting the engine(s).

 Wipe any spillage completely and dispose of rags

or waste on shore.

 Secure the fill cap tightly.

Fuel tanks should never be filled to capacity. al-

low 2% for expansion.

 Portable tanks should only be filled while on the

ground; never on-board the boat.

160 Dauntless - Owners Manual

Section 4 - Electrical System

Electrical System

CAUTION

Never reset a breaker without first determining and

correcting the cause of the trip. Should a circuit re-

peatedly trip, have a qualified electrician determine

and correct the cause.

 Never use an open flame in the battery storage

area.

 Avoid striking sparks near the battery

 A battery will explode if a flame or spark ignitesthe

free hydrogen given off during charging.

 The battery should always be disconnected before

doing any work or maintenance on the electrical sys-

tem.

CAUTION

If equipped with a battery switch, you will need to stop

the engine before moving the switch to the OFF po-

sition.

CAUTION

Batteries contain sulfuric acid which is dangerous and

can cause serious injury.AVOID contact with skin, eyes

and clothing. If contact occurs, immediately flush the

affected area with large quantities of water and call

for medical assistance

DANGER

Always store the battery in the the battery box. Use

the straps and clamp to keep the box secure while

underway.

NOTICE

Battery Information

Your 160 Dauntless is equipped with

an electrical system that provides

power for the following:

 Engine ignition

 Engine tilt trim system

 Helm switch panel & helm instrument panel

 Lighting/Navigation system

 Add-on accessories, options and electronics

The battery box is located under the aft starboard

quarter seat. Your battery should always be enclosed

in the covered battery box provided with your boat.

The box will contain any spilled acid, as well as pro-

tect the battery terminals from damage or inadvertant



shorting from coming in contact with metal objects.

The battery box should always be secured in place

by using the straps and clamps provided, the straps

will ensure that while underway the battery will not

move around, causing damage to components stored

in the same area.

Battery Maintenance

The most life shortening experience for the battery is

to be drained to zero charge before recharging. When

a battery discharges, the active material on both posi-

tive and negative plates converts to lead sulfate, caus-

ing the plates to become more alike in an electrical

charge. The electricity conducting battery acid be-

comes weaker and the voltage drops. As the battery

remains discharged, the process continues until re-

charging the battery becomes impossible. If the bat-

tery does become run down be sure to recharge it as

soon as possible. Over charging the battery can be just

as detrimental to its life as running it down too far.

Battery maintenance should include:

 Inspect the battery and charging system be-

fore each use for loose connections or wiring.

 Coat the terminals with dielectric grease.

 Keep the battery safe and dry.

 Remove the battery from the boat during

cold weather or long term storage.

Battery Box

Release Strap

Tie-down

strap

Battery Options

The 160 Dauntless can be equipped with the wiring

and connections for one (1) optional battery, with

the power being routed to the trolling motor panel

located in the bow of the boat, just forward of the

anchor locker. The spare battery will be located in-

side the console. Check with the trolling motor

manufacturers recommendation on breaker size, If

a larger breaker is needed, the wire size should ac-

commodate such a change.

Please have an authorized Boston Whaler® dealer

install the trolling motor to ensure safety and reli-

ability.

160 Dauntless - Owners Manual

Section 4 - Electrical System

This owners manual contains schematics for your boat. These electrical schematics were generated

by technicians in our Engineering Department and are for reference and to be used by service

technicians.Boston Whaler® does not recommend that you attempt to work on the electrical system

yourself, instead we suggest that you take it to an authorized Boston Whaler® dealer for electrical

service. Boston Whaler® reserves the right to change or update the electrical system on any model at

any time without notice to the consumer and is not obligated to make any updates to units built prior to the changes.

This schematic is to be used for reference only. If you should need to have your electrical system serviced, please take

it to an authorized Boston Whaler® dealer.

Electrical System

160 Dauntless Electrical

Schematic

HORN NAV/ANC BILGE PUMP

STEREO

ACC-1 12V

RECEPTACLE

12V

WATE R

PRESSURE

VOLT

FUEL

x1000

RPM

160 Dauntless - Owners Manual

Section 4 - Electrical System

1 Instrument panel, Analog

2 Tachometer, Analog

13 Water Pressure Gauge, Analog

4 Voltmeter, Analog

5 Fuel Gauge, Analog

6 12 Volt Receptacle Plug

7 12 Volt Receptacle Plug, 10 Amp Breaker

8 Horn

9 Horn Switch, 5 Amp Breaker

Instrument Panel

160 Dauntless Instrument Panels

10 Nav/Anc Switch

11 Nav/Anc Switch, 5 Amp Breaker

12 Bilge Pump Switch

13 Bilge Pump Switch, 5 Amp Breaker

14 Stereo Switch

15 Stereo Switch, 15Amp Breaker

16 Accessory 1 Switch

17 Accessory 1 Switch, 10 Amp Breaker

160 Dauntless - Owners Manual

Section 4 - Electrical System

The 160 Dauntless has the option of using a battery

switch. The switch; located aft starboard under the

sterndeck hatch opposite the livewell, allows you to

control the delivery of DC power from the battery(ies)

to the engine as well as allowing the alternator to

charge the battery(ies). Your battery selector switch

has two settings, ON and OFF, ON gives you

power from the number one (1) battery only. Remem-

ber to turn the battery selector switch to ON be-

fore you attempt to start your engine.

Note: The auto bilge pump cannot be turned off with

the battery selector switch.

Battery Switch (optional)

Battery

Selector

Switch

Your 160 Dauntless comes equipped with naviga-

tion lighting for your safety. Regulations state that

all boats no matter the size must display navigation

lights.

OPERATION:

Control of the navigation lighting is a switch on the

instrument panel that is marked NAV/ANC. The

switch has 3 positions to operate the Navigation/

Anchor lighting.

Navigation Lighting

While underway the aft pole light may be obscured by

the angle of the hull or by having the canvas top

in the open position

NOTICE

112.5° port

navigation

light, (red)

112.5° starboard

navigation

light, (green)

360° all-

round light,

(white)

Ignition Shutdown Switch

Wear your lanyard at all times while operating the boat.

It is for emergency stopping only. Do not use it to shut

off the engine during normal operation. The lanyard

should be long enough to prevent inadvertent activation.

CAUTION

The 160 Dauntless is equipped with an ignition shut-

down safety switch. It is located starboard of the steer-

ing wheel, below the ignition switch. The ignition

shut down safety switch incorporates a shut-off

switch, switch clip, lanyard and lanyard clip, which

is clipped to the operator. If an emergency arises

where the engine must be shut down, a pull on the

cord to release the clip from the shut-off will shut

down the engine. This switch is designed to shut the

engine off when the operator of the boat leaves the

control station, either accidentally by falling into the

boat, or by being ejected overboard. This would most

likely occur as a result of poor operating practices.

Ignition Shut-down

Switch

IgnitionShut-down

Switch Plate

Lanyard

Ignition Shut-down

Switch Clip,

(attaches to switch)

Ignition Shut-down

Switch Clip,

(attaches to you)

160 Dauntless - Owners Manual

Section 5 - Bilge System

NOTICE

Bilge Pump

The 160 Dauntless is equipped with

an 1100 GPH pump and is operated

by a float switch that will activate au-

tomatically when water in the bilge

reaches a certain level.

OPERATION:

There is a switch marked BILGE PUMP on the

instrument panel. Depressing the switch will ener-

gize the pump regardless of the position of the float

switch. The pump discharges water overboard via a

thru-hull fitting.

MAINTENANCE:

The bilge pump is accessed through a utility hatch

located in the transom motorwell. The bilge pump is

a completely sealed unit and maintenance is very

simple, but it will require you to check around the

float switch for debris and gummy bilge oil that could

impede the bilge pump from working properly.

Check the bilge pump and hoses for wear; clean and

repair if neccessary.

1 1100 GPH bilge pump

2 Float switch

3 Bilge pump hose

4 Bilge pump outlet

The bilge pump is wired directly to the battery. Be

sure that the bilge pump float switch is clear of debris

to prevent continuous operation and subsequent dis-

charge of the battery.

160 Dauntless Bilge Diagram

Livewell (optional)

The 160 Dauntless can be equipped with a livewell

that is located under Reversible pilot seat. The

livewells primary function is to keep baitfish alive

by circulating fresh seawater into the tank.

OPERATION:

The livewell can be filled by pressing the switch

marked LIVEWELL on the instrument panel.

There is a tube in the livewell that will prevent the

system from overflowing. Any excess water will be

drained out through the transom.

MAINTENANCE:

Maintenance of the livewell system will require you

to check the pump opening for debris and impedi-

ments, this can be done visually on dry land. The

pump opening is located on the aft part of the hull on

the starboard side.

Optional Livewell

location, (under seat)

160 Dauntless - Owners Manual

Section 6 - Propulsion System

Propeller Information

Under no circumstance use a propeller which allows

the engine to operate at a higher than recommended

RPM.

NOTICE

It is advised that you always carry a spare propeller,

propeller hardware and propeller wrench on board.

Should your propeller become damaged it can be eas-

ily replaced.

Disconnect power by moving the battery switch to the

OFF position prior to removing the propeller.

DANGER

The engine on the 160 Dauntless has

been equipped with a propeller;

which our tests have shown to be

best suited for general use under nor-

mal conditions and load. In some

situations you may wish to change the propellers to

give your boat slightly different performance char-

acteristics. Changing your boats running surface, such

as the addition of bottom paint will affect the type

and size of propeller required.

In general, changing to a lower pitch propeller will

increase acceleration and load pulling capability, with

a slight decrease in top end speed. If you choose to

change propellers, the type should be discussed with

your Boston Whaler® dealer.

All propellers are designed to provide maximum for-

ward thrust, so the reverse thrust of the propeller will

not be as efficient.

Propeller Assembly

8 Diffuser ring

9 Blade back

10 Blade root

11 Outer hub

12 Inner hub

13 Exhaust passage

14 Drive sleeve adapter

15 Lock ring

16 Prop nut

1 Shaft, (from en-

gine)

2 Forward thrust

washer

3 Drive sleeve

4 Blade face

5 Leading edge

6 Blade tip

7 Trailing edge

1 Propeller Diameter

2 1 Revolution, (Pitch)

3 Propeller Rake

160 Dauntless - Owners Manual

Section 6 - Propulsion System

Shift only when engine is running. Pause in neutral

while shifting, wait for boat to lose headway, and then

shift quickly. Easing into gear can damage the en-

gine.

CAUTION

Gear Shift & Throttle Control

The 160 Dauntless is equipped with

a gear shift/throttle control unit

mounted on the console directly star-

board of the steering wheel. The gear

shift/throttle control unit for the en-

gine activates both shifting mechanism and throttle.

The control must be in the NEUTRAL position to

start your engine. Neutral is the most upright posi-

tion of the control unit and acts as an idle, the pro-

peller is not rotating. There is a throttle only but-

ton at the center of the throttle control that when de-

pressed will disengage the shifting mechanism and

will allow you to operate the throttle without engag-

ing the propeller. This button will automatically en-

gage the shifting mechanism once the throttle con-

trol has been moved back to its center position (you

will hear and feel a click when it is engaged). Mov-

ing the lever forward engages the forward gear and

then the throttle advance.

Throttle

Control

Lever

Power

Trim

Switch

FORWARD

REVERSE

NEUTRAL

Throttle

ONLY

Button

To reverse power, bring the control lever back to en-

gage the reverse gear and increase the reverse thrust.

The throttle control regulates the RPM of the engine.

Regulating the RPM of the engine will control the

speed of the boat. Pulling back on the gear shift/

throttle control while moving at a high speed will

cause a sudden slowing of the boat and will create a

following wake which may rise above the transom

and flood the boat. Understanding your boat and its

reactions at speed will make boating for you safer

and more enjoyable.

Power Trim Operation

The power trim & tilt system allows you to raise and

lower the engine outdrive for trailering, launching

and beaching. This also allows for ideal boat angle

(in relation to the water surface) for a given load and

water condition. In most cases, best all-round per-

formance is obtained with the engine adjusted so that

the boat will run at a 3° to 5° angle to the water. The

power trim is located on the inboard side of the gear

shift/throttle lever handle.

NOTE: Boats can be operated in a manner and at

certain speeds resulting in trim angles that could

cause visibility to be obscured. Motor trim, hull trim

plane angles (if equipped), boat load distribution

and speed are factors that affect a boats trim angle.

Power Trim Switch Detail

Push to trim

engine UP

Push to trim

engine DOWN

160 Dauntless - Owners Manual

Section 6 - Propulsion System

Your 160 Dauntless is equipped with

a teleflex no-feedback steering sys-

tem. The Teleflex no-feedback steer-

ing system has a clutch mechanism

which prevents the engine torque

from being felt at the steering wheel. This reduces

driver fatigue by eliminating the constant need to

fight the wheel.

Operation:

Steering the boat is based on applying thrust to the

engine and turning the steering wheel. Because the

engine is mounted at the stern of the boat, the turn

will generate from there; whereas a cars turn is based

around the front wheels. It is important to understand

that thrust is required to make a turn. If engine main-

tenance neglected; it could stall at a critical time and

cause injury and damage to your passengers and your

boat.

Maintenance:

The mechanical steering system should be checked

periodically by your Boston Whaler® dealer for

proper lubrication, alignment and to make sure there

is no looseness or binding of the cable. Proper main-

tenance of this system will ensure worry-free usage

for the life of your boat.

No-feedback steering system maintenance should

include the following:

 After the first few hours of operation and at regu-

lar intervals, check all fasteners and the complete

steering system for security and integrity.

 Check all moving parts to be sure they are free

of salt build-up and other foreign material. Such

build-up will affect their operation.

Steering Information

Do not cover cracks in the steering cable or fittings

with tape or other sealants. This will create a hazard in

which the cable can fail without warning.

CAUTION

Steering

Trim

Tab

Steering pull is unnecessary and unsafe! Steering trim

tabs provided on most engines are frequently improp-

erly adjusted, (they work opposite to normal expec-

tation).

To set steering trim tab for neutral steering:

There is a bolt on the underside center of the tab;

loosen the bolt prior to adjustment.

If boat veers to the right, (hands off), move the aft

end of the tab to the right.

If boat veers to the left, (hands off), move the aft end

of the tab to the left.

Steering Pull

1 No Feed Back (NFB) Steering Base

2 NFB Steering Cable

3 NFB Steering Link Rod

4 NFB Engine Cylinder

5 Steering Wheel Tilt Lever

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Boston Whaler 160 Dauntless Owner's manual

Boston Whaler 160 Dauntless Owner's manual

Boston Whaler 160 Dauntless Owner's manual

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