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 #1647858
The mission of Boston Whaler® is
to provide consumers with the
safest, highest quality, most durable
boats in the world
Rev C 05/12/04
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 wont 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 OWNERS 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 - Owners 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 10
Empty Tank 10
Hoses & Fittings 10
Tank Cleaning 10
Fuel Filter 10
Static Electricity and the Fuel System 11
Section 4-Electrical System
Electrical System 12
Battery Information 12
Battery Maintenance 12
Battery Options 12
Electrical Schematic 13
Instrument Panels 14
Battery Switch, (optional) 15
Navigation Lighting 15
Operation 15
Ignition Shutdown Switch 15
This Owners Manual has been written to provide specific information about your boat and it should be read carefully.
Keep this booklet with the Owners Manual in the Owners Manual Packet.
The Owners 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, its systems and information on its operation and maintenance.
Please familiarize yourself with the boat and its 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
1
Section 1 - 160 Dauntless
160 Dauntless - Owners Manual
2
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.
2
3
4
1
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 - Owners Manual
3
163
71
49
11
86
*
Note: The canvas top shown here is
for reference purposes only.
***
199
Overall Length 163 4.95 m
Trailerable Length 199 6.02 m
Bridge Clearance 86 2.59 m
Bridge Clearance (no top)49 1.45 m
Beam 71 2.15 m
Draft, (Hull Only) 11 .27 m
Weight (dry, no engine) 1300 lbs. 589 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
!
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 - Owners 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 ELPTO Mercury engine
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
4
5
678
9
101112
131415
19
20
17
18
16
21
160 Dauntless
Standard Features
22
23
26
25
160 Dauntless - Owners 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 90 ELPT 4-Stroke Mercury Engine
19 90 ELPT OptiMax Mercury Engine
20 115 ELPT EFI 4-Stroke Mercury Engine
21 115 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
8
6
7
5
3
1
2
Livewell detail,
backrest and cushion
removed for clarity.
13
14
12
11
15
16
17
To reversible pilot seat
livewell, fill
4
9
10
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)
1
2
3
4
5
6
18
19
20
21
160 Dauntless - Owners 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
5
4
6
3
5
7
3
2
1
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
!
6
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
1
2
3
See Detail
A
See Detail
B
Detail
A
4
5
7
8
160 Dauntless - Owners 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
160 Dauntless - Owners 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 af fect
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 OWNERS 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 - Owners 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 owners 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 owners manual
packet.
Follow the engine manufacturers 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
1
2
Fuel fill
3
4
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 - Owners 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.
FUEL FILTER:
The 160 Dauntless may be fitted with an in-line fuel/
water separator. This fuel filter system helps to keep
your engine and carburetor free from water, contami-
nated fuel and small particles. The fuel/water sepa-
rator can be accessed through the starboard aft quar-
ter seat. Replace the fuel/water separator at regular
intervals or when loss of power is noticed. The filter
can be removed using a standard oil filter wrench
and should not be over-tightened. It is also recom-
mended that a spare filter be carried, as one tankful
of contaminated fuel can plug a filter. Some engines
have an integrated fuel filter and should not be
equipped with an additional fuel filter. The additional
load on the fuel pump could cause performance prob-
lems or engine damage, check your engine owners
manual for more information or contact your autho-
rized Boston Whaler® dealer.
Fuel supply
line from tank
Fuel supply
to engine
Filter,
(twist-off)
160 Dauntless - Owners Manual
Section 4 - Electrical System 11
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 liklihood of static discharge.
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.
Static Electricity and the Fuel System
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 - Owners Manual
Section 4 - Electrical System12
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.
A void striking sparks near the battery
A battery will explode if a flame or spark ignites the
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
manufacturers 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 - Owners Manual
Section 4 - Electrical System 13
This owners 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
HORN NAV/ANC BILGE PUMP
STEREO
ACC-1 12V
RECEPTACLE
12V
WATER
PRESSURE
VOLT
8
0
1
18
FUEL
EF
2
3
4
5
6
x1000
RPM
160 Dauntless - Owners Manual
Section 4 - Electrical System14
1 Instrument panel, Blank
2 Horn Switch
3 Horn Switch, 5 Amp Breaker
4 Nav/Anc Switch
5 Nav/Anc Switch, 5 Amp Breaker
6 Bilge Pump Switch
7 Bilge Pump Switch, 5 Amp Breaker
8 Stereo Switch
9 Stereo Switch, 15Amp Breaker
10 Accessory 1 Switch
11 Accessory 1 Switch, 10 Amp Breaker
12 Instrument Panel, Analog
13 Tachometer, Analog
14 Water Pressure Gauge, Analog
15 Voltmeter, Analog
16 Fuel Gauge, Analog
17 12 Volt Receptacle Plug
18 12 Volt Receptacle Plug, 10 Amp Breaker
Instrument Panel,
Blank
160 Dauntless Instrument Panels
3
2
15
4
7
6
9
8
11
10
Instrument Panel, Analog
13
12
15
14
16
18
17
160 Dauntless - Owners Manual
Section 4 - Electrical System 15
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
W ear 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 - Owners Manual
Section 5 - Bilge System16
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
livewells 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.
1
3
4
2
Optional Livewell
location, (under seat)
160 Dauntless - Owners Manual
Section 6 - Propulsion System 17
Propeller Information
Under no circumstance use a propeller which allows
the engine to operate at a higher than recommended
RPM.
NOTICE
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
2
3
4
5
6
7
8
9
10
15
11
12
13
14
16
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
2
3
1 Propeller Diameter
2 1 Revolution, (Pitch)
3 Propeller Rake
160 Dauntless - Owners Manual
Section 6 - Propulsion System18
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 boats trim angle.
83
'1
Power Trim Switch Detail
Push to trim
engine UP
Push to trim
engine DOWN
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