2001 160 Dauntless Fuel Fill Cap Wrench

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2001 160 Dauntless Fuel Fill Cap Wrench

Postby glurtis » Wed Dec 27, 2017 1:55 pm

I just bought [a 2001 Boston Whaler 160 DAUNTLESS] boat; I am new to the Whaler family. The fuel tank cap has two holes and a rounded slot between them. Is there a special wrench required to open the cap?--glurtis

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Re: 2001 160 Dauntless Fuel Fill Cap Wrench

Postby Todd » Wed Dec 27, 2017 2:39 pm

Hello and congratulations!

I have a 2003 160 Dauntless myself. The [fuel fill cap] is pretty much flush to the stern so it doesn't collect debris and can literally be stepped on if necessary. There is a simple key for these applications, it looks like this:

https://www.wholesalemarine.com/perko-b ... gK3OvD_BwE

If yours has a 45-gallon fuel tank like mine, you wont need to put in fuel very often. One suggestion you may already know about: buy gasoline that is not blended with ethanol.

Best wishes on the great boat!


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Re: 2001 160 Dauntless Fuel Fill Cap Wrench

Postby jimh » Wed Dec 27, 2017 3:49 pm

I suspect you probably have a fuel tank filler cap that resembles this one:


I am certain that when the 2001 Boston Whaler boat was delivered, there was a wrench or key for that filler cap included. Check around the boat for one. Perhaps it is stored somewhere.

When you find it, the first thing you need to do is attach a float to it. Those filler keys are very prone to falling into the water. For a float, you need to get several of these:



Put your boat ignition keys on a Whaler float, and your fuel filler cap wrench on another, and maybe any keys for boat storage cabinets or trailer locks on a third float.

Also, check the status of the retainer for the filler cap. Usually they are retained by a small chain or a small diameter aircraft cable. However, the chain may be worn. Use care when removing the filler cap.

On my 1990 Boston Whaler the filler cap chain is now loose. I actually like it that way. As soon as I unthread the cap I put it back inside the boat. The thought of the filler cap loose and dangling over the water on a 25-year-old little chain makes me nervous.

Also--make duplicate keys for the boat ignition and any cabinet door locks. Keep them somewhere on the boat in an inconspicuous place, maybe way down at the bottom of a locker (that you don't keep locked) under a bunch of other stuff.

Also--the dock attendant at most fuel docks will have a wrench for that filler cap, but you will need one at the highway fuel station. That is why I generally keep the boat keys in the truck glove box. When buying fuel at a highway fuel station, I don't have to get on the boat and look for the filler cap key.

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Re: 2001 160 Dauntless Fuel Fill Cap Wrench

Postby ConB » Wed Dec 27, 2017 7:48 pm

In a pinch a pair of needle nose pliers will open that type of fuel fill cap. A nose in each hole and turn the handles.

Last edited by ConB on Thu Dec 28, 2017 2:38 pm, edited 1 time in total.
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Re: 2001 160 Dauntless Fuel Fill Cap Wrench

Postby lhorn42 » Thu Dec 28, 2017 12:34 pm

The back of a closed blade on my 3 1/2" Spyderco folding knife fits the slot in this fuel cap perfectly.

2003 160 Dauntless purchased used in 2008. No fuel key in otherwise complete documentation from seller. I've see the appropriate key on rings at various fuel docks, so that part must be available somewhere.

Good luck!


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Phil T
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Re: 2001 160 Dauntless Fuel Fill Cap Wrench

Postby Phil T » Thu Dec 28, 2017 1:53 pm

The technical term for it is a DECK PLATE FILL KEY.

Perko makes a plastic version: https://www.fisheriessupply.com/perko-deck-plate-key-1247dp0blk
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