Boston Whaler 320 Outrage User manual

The mission of Boston Whaler® is to
provide consumers with the
safest, highest quality, most durable
boats in the world
INFORMATION IN THIS PUBLICATION IS BASED ON THE LATEST PRODUCT SPECIFICATIONS AVAILABLE AT PRINTING, BOSTON WHALER® BOATS, INC. RESERVES THE RIGHT
TO MAKE CHANGES ATANYTIME 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:
320 OUTRAGE, BOSTON WHALER®. MRP #1738209
Rev D 05/20/04

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 accomplishments
made in marine engineer-
ing and construction.
History
In 1958, company founder Richard T. Fisher introduced the first Boston Whaler boat in Braintree, assachussetts. 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 durable, 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 underway, the boat being sawed in half and ulti-
mately 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 transferable 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 BOOK AND OTHER MATERIALS IN A SECURE PLACE, AND BE SURE TO HAND IT
OVER TO THE NEW OWNER IF YOU SELL THE BOAT.
This Owners anual has been written to provide specific information about your boat and it should be read carefully.
Keep this booklet in the Owners anual Packet. The Owners anual 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 - 320 Outrage
Table of Contents
Seacock Operation 29
Head System 30
Dock-Side Discharge 30
Standard Waste System Diagram 30
Optional Inland Waters Diagram 30
Macerator 31
Operation Maintenance 31
Environmental Considerations 31
Section 6 Bilge System
Bilge Pump System Diagram 32
Operation Maintenance 32
Section 7 Livewell System
Livewell 33
Operation 33
Flow Control Valve 33
Maintenance 33
Livewell System Diagram 33
Section 8 Propulsion System
Hydraulic Steering Information 34
Operation Maintenance 34
Power Steering Information 35
Gear Shift & Throttle Control 36
Digital Throttle & Shift (DTS) 36
Power Trim Operation 37
Helm Seat Track Maintenance 37
Propeller Information 38
Propeller Assembly 38
Section 9 Getting to know your Boston Whaler
Trim Tabs-Operation Maintenance 39
Mooring Points Lifting 40
Hull Maintenance 41
Hull Maintenance (Blisters) 41
Bottom Painting 41
Painted Hull Care (Bottom) 42
Vinyl Cushion Care 42
Long Term Storage 42
Engines 42
Fuel System 42
Trailer Storage 42
Electrical System 42
Drainage 42
Canvas Care & Maintenance 43
Trailer (Optional) 44
Trailer Safety 44
Bunk Trailer Terminology 44
Section 10 Anchoring Information
Anchoring Information 45
Lowering 45
Setting 45
Weighing 45
Anchor Windlass 46
Operation 46
Lowering 46
Raising 46
Emergency Operation 46
Section 11 Maintenance Log & Notes
Maintenance Log & Notes 47
Section 12 (ADSS)Active Deck Suspension System
ADSS Description 1
ADSS Operation Maintenance 2
320 Outrage-Owners Manual
Section 1 320 Outrage
Table of Contents 1
Construction Standards 2
Our Hull 2
Servicing your Boston Whaler 2
Hull Identification Number 2
Section 2 General Arrangement & Specifications
Specifications & Dimensions 3
Standard Features 4-5
Notable Options 6
Storage 7
Through-hull Fittings 8
Deck Occupancy 9
Canvas Arrangment 10
Standard Seating Arrangement 10
Label Locations 11
Section 3 Fuel System
Fuel System 12
Fuel Tank 12
Fuel Fill 12
Fuel System Diagram 12
Fuel Vent 13
Primer Bulb 13
Tank Selection 13
Empty Tank 14
Hoses & Fittings 14
Tank Cleaning 14
Remote Oil System 14
Static Electricity and the Fuel System 15
Section 4 DC Electrical System
Battery Information 16
Battery Box Locations 16
Battery Maintenance 16
Dual Battery Switches 17
Instrument Panel Wiring Diagram 18
Battery & Switch Diagram 18
Main Breaker Panel Wiring Diagram 19
Hull Wiring Diagram 19
ADSS Wiring Diagram 20
Waste System-Inland Waters Diagram 20
Waste System-Overboard Discharge Diagram 20
Anchor Windlass Wiring Diagram 20
Instrument Panel Arrangement 21
Multi-System Tachometer 21
Multi-System Speedometer 21
Ignition Shutdown Switch 22
Electric Downrigger Receptacles 22
Main Breaker Panel 23
Engine Starting Procedure 24
Navigation Lighting 25
Shore Power 26
Operation 26
Battery Charger 26
Section 5 Water & Waste System
Freshwater System & Diagram 27
Freshwater Pump 27
Freshwater Shower 27
Maintenance 28
Disinfecting the System 28
Winterizing the System 28
Raw Water 29
Operation Maintenance 29
Raw Water System Diagram 29
1

Section 1 - 320 Outrage
320 Outrage-Owners Manual
THE MISSION OF BOSTON WHALER IS TO PROVIDE CONSUMERS WITH THE
SAFEST, HI HEST 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 acht
Council (A.B. .C.) and certified by the National Marine Manufacturers Association (N.M.M.A.).
Construction Standards
2
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. lso 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
Hull
Identification
Number Location
When your 320 Outrage needs to be serviced or regu-
lar 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
1
1No air voids
2High density closed cell non-absorbent foam
3High quality resins and gelcoats
4Woven glass matting

Section 2 - General Arrangement & Specifications
320 Outrage-Owners Manual
3
322
102
356
110
910
*
811
Overall Length 322 9.80 m
Trailerable Length 356 10.8 m
Bridge Clearance 910 3.00 m
Beam 102 3.10 m
Draft, (Hull Only) 110 .56 m
Weight (dry, no engine) 8500 lbs. 3855 kg
Swamped Capacity 4800 lbs 2177 kg
Maximum Engine Weight 1220 lbs 553 kg
Maximum Weight,
(passengers,engine(s),
gear,** 4300 lbs 1950 kg
Persons 14
Maximum Horsepower 600 HP 447 kw
Minimum Horsepower 400 HP 298 kw
Fuel Capacity 300 Gal.(U.S.) 1135 L
Water Capacity 40 Gal.(U.S.) 151 L
Waste Capacity 6.5 Gal (U.S.) 24 L
* Waterline
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 bost’s perfor-
mance. DO NOT Exceed the weights listed on the
capacity plate.
NOTICE
!
**
Hardtop removed for clarity

Section 2 - General Arrangement & Specifications
320 Outrage-Owners Manual
4
Standard Features
1Heavy Duty Rubrail
2Anchor Locker w/ Drain
3Bow Navigation Lights, Port/Starboard)
4Stainless Steel Fwd. Cleats, Port/Starboard)
5Welded Stainless Steel Low Profile Interior Rail
6Forward Bolsters
7Forward Seat, Storage Under)
8Forward Port Seat, Storage Under)
9 Forward Starboard Seat, Storage Under)
10 Forward In-Deck Fishbox, Insulated
11 Forward In-Deck Storage
12 Forward Rodholders, 4-Port/Starboard)
13 Forward Cupholders, 2-Port/Starboard)
14 Self Bailing Cockpit
15 Forward Console Seat
SEE CONSOLE DETAIL
16 Molded Tempered Glass Windshield
17 Compass with Light
18 Electronics Box Door, Lockable
19 Instrument Panel
20 Stainless Steel Steering Wheel w/ Knob
21 Gear Shift/Throttle Control
22 Molded Console Footrests
23 Electronics Box Mounting Surface
24 Console Door, Lockable
25 Portlight w/ Screen
26 Console Cupholders, 2)
27 Port Fuel Fill
28 Stainless Steel Spring Cleat, Port & Starboard
29 Gunwale Mounted Rodholders, 2)Port & Starboard
30 Port Fishbox, Insulated
31 Stainless Steel Hawse Pipe, Port & Starboard
32 Stern Rodholders, 3)
33 8 Inch Access Plate, Port & Starboard
34 Transom Oil Fill, 2)
35 Motorwell Drain, Port/Starboard)
36 Dual 225 CXXL Mercury Engines
37 Motorwell Access Hatch
38 Telescoping Ladder w/ Lid
39 Transom Door
40 Cockpit Drains
41 Starboard Fishbox, Insulated
42 Starboard Fuel Fill
43 Waste Pumpout
44 Stern Foldaway Seat
1 2
3
4
56
7
89
10
11
12
13
14
15
16
17
18
19
20
21
23
22
25
24
26
27
28
29
30
31
32
33
34 35
36
37
38
39
40
41
43
42
44

Section 2 - General Arrangement & Specifications
320 Outrage-Owners Manual
1Prep Station
2Prep Station, Tackle Center
3Pull-out Sprayer with Sink
4Prep Station Rodholder, (2)
5Prep Station ivewell
6Prep Station ivewell Access
7Freshwater Fill
8Raw Water Connection
9Vacu-Flush Toilet
10 Vertical Rodholder
11 Freshwater Sprayer and Sink
12 Downrigger Weight Holder
13 Transom Shower
14 Hardtop, Fiberglass
15 ifejacket Storage
16 Electronics Box
17 Hardtop Courtesy ights
18 Map ight (RED)
19 Spreader ights
20 Hardtop Hatch
21 Stainless Steel Toe
Rails, Port/Starboard
22 Electric Trim Tabs
23 Windlass & Anchor
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
21
22
17
19 18
20
23
24
25
26
24 Swivel & anyard
25 Remote Storage
26 Remote Connection
Standard
Features

Section 2 - General Arrangement & Specifications
320 Outrage-Owners Manual
6
320 Outrage, Notable Options
1Hull Colors-
Yellow w/ Black Graphics,
Fighting Lady Yellow w/ Black Graphics,
Light Blue w/ Black Graphics
Wasabi w/ Black Graphics
2 Red or Blue Graphics, Striping & ogos
3Tall Bow Rail
4 Radial Outriggers for Hard-Top
5225 CXX EFI 4-Stroke Mercury Dual Engines
6225 CXX DTS OptiMax Dual Engines
7250 CXX DTS Verado 4-Stroke Dual Engines
8275 CXX DTS Verado 4-Stroke Dual Engines
912V Receptacle, port & starboard gunwales-(aft)
10 Butane Stove, Portable
11 Bow Tow Eye
4
5
6
9
10
2
3
1
11
7
8

Section 2 - General Arrangement & Specifications
320 Outrage-Owners Manual
7
1Pocket Storage, Port
2Console Storage, Port
3Gunwale Tip-Out Bin, Port
4Under Gunwale Rod Storage, Port
5Downrigger Ball Storage, Port
6Pocket Storage, Starboard
7Fire Extinguisher Pocket
8Console Storage, Starboard
9Gunwale Tip-Out Bin, Starboard
10 Under Gunwale Rod Storage, Starboard
11 Downrigger Ball Storage, Starboard
12 ifejacket Storage, Hardtop
13 ockable Electronics Box, Hardtop
14 Anchor ocker with Drain
15 24 Gal. (91 ) Storage Well, (under forward seat)
15
17
16
18
19
20
21
22
23
24
25
26
13
Storage 12345
78910 11
614
16 108 Gal. (409 ), Forward Insulated Fishbox
17 80.5 Gal.(305 ) Forward ocker Starboard
18 Forward In-Deck locker
19 Console, ockable
20 Console Cupholder, (2)
21 Swim adder Stowage
22 Motorwell Access, Oil Tank Storage
23 Port Fishbox, 80 Gal.(302 ) (Starboard is same)
24 Console Electronics Box, ockable
25 Forward Cupholder, (Starboard is Identical)
26 80.5 Gal. (305 )Forward ocker, Port
27 Tackle Storage
28 Knife Storage
29 Storage Bin (in front)
30 Rodholder, Prep Station
31 Cupholders (2), Prep Station
32 Knife/Tool Holder in Door
WARNING
No Ventilation is provided. Fuel vapors are a fire and
explosion hazard. To avoid injury or death, DO NOT
store fuel or flammable liquids in any of these areas.
!
28
31
30
27
29
32
Underside of T-Top,
(looking up)
12

Section 2 - General Arrangement & Specifications
320 Outrage-Owners Manual
8
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 water in the
cockpit. the drain must be in place when underway.
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
!
Through hull fittings should be checked for proper
seal annually. When the boat is in the water the un-
derwater fittings can be checked for dripping. It is
recommended that the underwater fittings be re-
moved, 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
!
16 ivewell Drain
17 Garboard Drain
18 Active Deck Suspension System (ADSS) pan
drain, (Optional)
PORT
STARBOARD
1Anchor ocker Drain, Port
2Fuel Tank Vent, Port
3Raw Water/ ivewell Inlet
4Bilge Pump Outlet
5Fishbox Pump Outlet, Port
6Anchor ocker Drain, Starboard
7Sink/Deck Drain
8Bilge Pump Outlet
9Fishbox Pump Outlet, Forward
10 Waste Vent
11 Fuel Vent, Starboard
12 Macerator Discharge
13 Fishbox Pumpout, Starboard
14 Deck Drains
15 Motorwell Drains
320 Outrage,Through-hull Fittings
1
2
4
6
5
11 10
AFT
3
7
812
13
14
9
15
16
14
15
17
18

Section 2 - General Arrangement & Specifications
320 Outrage-Owners Manual
9
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.
DANGER
!
Working deck:
This area is intended for occupation ON Y
while mooring, anchoring, loading/unload-
ing or when the boat is at rest. NEVER op-
erate the engine while loading or unloading
swimmers/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.
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. NEVER sit on the gunwales (vertical
sidewalls), while the boat is moving.
WARNING
!
!

Section 2 - General Arrangement & Specifications
320 Outrage-Owners Manual
10
Injury and possible death can occur while sitting in ar-
eas of the boat that are not designated for seating.
Gunwales, sterndeck and portions of the bow should
not be used for sitting while underway. Movement of
passengers on the deck should be limited to decrease
the chances of slipping or falling while underway.
DANGER
!
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
12
3
Standard Seating Arrangement
1Helm & Companion seats with snap-on cushions,
(adjustable port seat).
2Forward Console eat
3Forward eating
4tern fold-away seat
4
320 Outrage Canvas Arrangement
1Bait Prep tation Cover, Black
2Console Cover, Black
3Weather Curtain Visor, Black or White
4Weather Curtain ides, Black or White
5Weather Curtain Wing, Black or White
1
2
3
4
5

If your labels become worn or unreadable contact
your nearest Boston Whaler®dealer for replace-
ment labels. The part numbers are provided below.
320 Outrage-Owners Manual
11
Section 2 - General Arrangement & Specifications
320 Outrage Label Locations
NOTICE
!

Section 3 - Fuel System
320 Outrage-Owners Manual
12
*(1(5$/
)8(/
The 320 Outrage 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 Tank
The 320 Outrage comes with 2-150 Gal. (568L)
aluminum fuel tanks. The tanks are located under
the aft section of the cockpit. Access to the fuel
level senders for each tank is through a plate on
the aft section of the cockpit floor.
Fuel Fill
The 320 Outrage has fuel fills for each tank, located
on the port/starboard sides amidship on the gunwales,
each is marked GA , and is opened by use of a
special key that is included with the owners manual
packet. Follow the engine manufacturers recommen-
dation for the types of fuel to use.
320 Outrage Fuel System
1Fuel Fill, Port tank
21-1/2 Fuel fill hose to deck plate
35/8 Fuel vent line
4150 Gal. (568L) Aluminum fuel
tank, Port
5Aluminum bracket, forward/Aft
6Fuel sender, Port tank
7Engine fuel supply
8 Ground wire, Port tank
9 Fuel pick-up
10 Port fuel selector valve
11 tarboard fuel selector valve
The starboard fuel tank is similar
in assembly and is not shown
in its entirety.
4
2
3
1
5
6
7
8
9
10 11
CAUTION
250 XS OPTIMAX ENGINES
Use only 92 Octane (R+M)/2 or 98 RON fuel. DO NOT
use pre-mixed gasoline and oil in this engine. Use a
recommended, fresh gasoline during and after the
engine break-in.
!
Fuel System
CAUTION
!
Leaking fuel is a fire and explosion hazard, inspect the
system regularly. Examine fuel tanks and exposed lines
for leaks and corrosion.
DANGER
!
Check for leaks in tubing, connections and hoses. Cor-
rect 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 se-
riously. Engine damage resulting from use of improper
gasoline is considered misuse of engine and will void
the warranty. Follow engine manufacturer ’s recommen-
dations regarding the types of fuel and oil to use.
CAUTION
!
Oil and fuel spills can be dangerous and can subject
offenders to severe penalties
NOTICE
!
Remove portable tanks from boat and fill from shore.
When fueling is complete, secure tanks to deck with
straps provided.
DANGER
!
Static electricity can ignite gasoline vapors causing
serious injury/death and/or destruction of property.
NOTICE
!
Fuel tanks should never be filled to capacity, allow 2%
for expansion.

Section 3 - Fuel System
320 Outrage-Owners Manual
13
To Engine
Motorwell
hatch
Primer
bulb
Tank Selection
There are a pair of 3-way gasoline valves that con-
trol the flow of fuel to the engines. The fuel system
is designed to have the port engine supplied by the
port fuel tank and the starboard engine by the star-
board tank. The valves can be used so both engines
can be supplied by either tank. (If both engines will
be run from one fuel tank the boat will eventually
list to the opposite side of the tank being used). The
valves have PORT STARBOARD OFF clearly
marked on the perimeter of each valve. Turn the valve
handles to the desired position for the appropriate
tank. Be sure to always check the level of each fuel
tank and position of fuel valves to prevent the boat
from becoming unbalanced while underway. The tank
selector gasoline valves are located on the aft wall
of the stern foldaway seat.
Fuel Valve
Fuel Valve
Location
Aft foldaway seat
has been removed
for clarity.
Primer Bulb:
There are a pair of primer bulbs that can be accessed
under the port and starboard sides of the motorwell
hatch. The primer bulbs are used to draw fuel from
the tank to the engine usually after the fuel has been
drained from the entire system. There are also in-
structions regarding proper use of the primer bulb in
the engine manufacturers handbook.
From fuel
tank Port Tank Starboard Tank
To Port
Engine To Starboard
Engine
Port Tank
Selector Valve
Starboard Tank
Selector Valve
Fuel selector valves (looking forward)
Fuel Key Fuel Fill
The fuel tank(s) have a fuel tank vents located
amidship 7-9 inches below the rub rail directly be-
low the fuel fill cap. 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 continued safe opera-
tion 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 fitting 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
Fuel Vent

Section 3 - Fuel System14
320 Outrage-Owners Manual
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 separators
and notice a loss in power consult a professional
tank cleaning contractor regarding this procedure and
proper disposal of residue and water.
Remote Oil Tank Location
(sterndeck has been removed)
Standard engine oil supply 2-3 Gal. (11.3L)
The 320 Outrage is equipped with a remote oil sys-
tem. This system consists of two 3-Gal.(11.3L) res-
ervoir tanks and hoses which contain and meter lu-
bricating oil to the engine(s). The tanks have an ex-
ternal fill located on the aft side of the cockpit tran-
som wall. Access to the tanks is through the
motorwell access hatch. When recapping the fill
make sure that it is secure to prevent spills and to
prevent the intrusion of water into the system. Your
remote oil tank is secured by a nylon strap and quick
release clip. Little maintenance is required for the
remote oil system aside from checking the hoses for
abrasions and cracks and hose clamps for proper
tightness. The tank should not be exposed to ultra-
violet light rain or seawater for extended periods of
time.
Remote Oil System

320 Outrage-Owners Manual
15
 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.
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
Section 3 - Fuel System

16 Section 4 - Electrical System
320 Outrage-Owners Manual
DC Electrical System
Battery In ormation
Your 320 Outrage is equipped with
a Direct Current (DC) electrical sys-
tem. All power to the boats systems
are provided by the batteries. The
batteries are continuously charged by
the engines alternator while the engines are running.
The following are powered directly from the batter-
ies.
 Engine ignition
 Engine tilt trim system
 Helm switch panel & helm instrument panel
 Lighting/Navigation system
 Livewell system
 Add-on accessories and electronics
The system consists of the following components:
 Battery boxes (3 standard)
 Battery switches
 Main & Branch circuit breakers
 Helm Ignition Switch & Instrument Panel
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

Batteries should always be enclosed in the covered
battery boxes provided with your boat. The box will
contain any spilled acid as well as protect the bat-
tery terminals from damage or inadvertant shorting
from coming in contact with metal objects. Each bat-
tery box should always be secured in place by using
the straps and clamps provided the straps will en-
sure that while underway the battery will not move
around causing damage to components stored in the
same area.
BATTERY BOX LOCATION:
The 3 standard battery boxes can be accessed through
a door in the aft section of the console interior.
Battery Box
Release Strap
Tie-down
strap
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 system.
If equipped with a battery switch, you will need to stop the
engine before moving the switch to the “OFF”position.
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.
Always store the battery in the the battery box. Use the
straps and clamp to keep the box secure while underway.
CAUTION
CAUTION
CAUTION
DANGER
NOTICE
!
!
!
!
!
Battery Maintenance
Battery maintenance should include:
 Inspect each battery and charging system before
use; for loose connections or wiring.
 If not using a sealed battery check & maintain
the water level. USE distilled water ONLY.
 Coat the terminals with dielectric grease.
 Keep the batteries dry.
 Remove the batteries from the boat during cold
weather or long term storage.
The most life shortening experience for the battery
is to be drained to zero charge before recharging.
Forward
Deck has
been
removed
Battery
Boxes

Section 4 - Electrical System
320 Outrage-Owners Manual
17
ALL
2
1
OFF
Your 320 Outrage uses a battery selector switch to
control delivery of D power from two batteries. The
battery switches are located below the breaker panel
on the aft bulkhead inside the console.
The dual battery switches have four (4) settings:
 OFF, you will have no power to the engine(s).
 ALL, you will have power from both batteries
at the same time. This parallels the batteries to
assist you in starting the engine(s), once the en-
gine is started the battery switch should be taken
off of the ALL setting, and set to charge either
battery .
 1, you will have power from the port battery only.
 2, you will have power from the starboard
batteries only.
When the engines are shut down or not providing a
charge, the system will draw power from the starboard
batteries. This will allow you to run all the boats func-
tions without affecting the port battery. You can run
the starboard batteries down and still start the engines
by moving the selector knob on the battery switches
to the ALL position. The battery switches are lo-
cated below the breaker panel on the aft bulkhead in-
side the console. When looking at the panel, the switch
on the left is for the port battery and engine, the right
switch is for the starboard battery and engine.
Dual Battery Switches Selector Knob
Battery 1
Selection
Battery 2
Selection
Batteries
OFF
Selection
Batteries
ALL
Selection
Dual Engine Battery Switch Configuration
Both batteries un-connected, preferred position when boat
is not in use.
STARBOARD ENGINE
ALL
2
1
OFF
Normal position while engaging in normal engine opera-
tions.
To parallel batteries, set both switches to the ALL po-
sition.
Return to normal operating positions after starting.
Do not operate boat with batteries in parallel, seri-
ous engine electrical damage may result.
WARNING
WARNING
ALL
2
1
OFF
ALL
2
1
OFF
ALL
2
1
OFF
ALL
2
1
OFF
ALL
2
1
OFF
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
PORT ENGINE
The bilge pump will still draw power from the batter-
ies, even if the switches are set to “OFF”.
!
!
When a battery discharges, the active material on both
positive and negative plates converts to lead sulfate,
causing the plates to become more alike in an elec-
trical charge. The electricity conducting battery acid
becomes weaker and the voltage drops. As the bat-
tery remains discharged, the process continues until
recharging the battery becomes impossible.
If the battery does become run down be sure to re-
charge it as soon as possible. Over charging the bat-
tery can be ust as detrimental to its life as running it
down too far.

18 Section 4 - Electrical System
320 Outrage-Owners Manual
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6<67(0
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 up-
date 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.
Instrument Panel
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○ ○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
Navigation Switch
Detail
Battery and Switch Diagram