Having arrived at a safe place close to the big cities of Osaka and Kobe, I decided to take on the engine repair. Based on the fact that if (or more likely when) I mess up, I can call in the professionals.
The job required the removal of the fuel injector, and trying to figure out why exhaust gasses and fuel were leaking out from it.
In order to remove the injector, I first had to remove the high pressure fuel return lines from all the injectors, so I could get those pipes out of the way. This was easy, the supply pipe for the bad injector was next. A few other bits of engine came off to help with acesss, then I could try to pull the injector out.
I expected this to be difficult, and when I tried, it was just completely seized in, I guess this was to be expected, carbon buildup on the inside is normal. I believe there is a tool to help pull these injectors, but there was little chance of me getting hold of one. I visited a local hardware store to see if I could build something, but I couldnt find a bolt with the right thread to screw into the injector, so gave up. I put the whole thing back together and thought if nothing else I might have learnt how to remove the high pressure lines. Amazingly the engine still worked, and I couldnt see any fuel leaks. So nothing was lost.
Chatting with the locals here at the sailing club, one member with experience of engines came along to help the next day. I stripped it all down again and he had a go at removing the injector, he couldn’t extract it, but did manage to rotate it a degree or two. I had assumed the injector was keyed and so didn’t try to rotate it. I’m very conscious that an injector is a very high precision device and I’m worried about damaging it in any way by using too much force on it. However after the engineer gave up, I continuing to wiggle it back and forth whilst applying liberal amounts of WD40, eventually it paid off and the injector pooped out.


Here you can see the copper washer close up, there is a chunk missing, perhaps 0.5mm deep which I hoped was the cause of the problem. A trip to the local hardware store failed to find anything close to the right size so I need to order the correct replacement.
In the meantime I carefully sanded down the washer to make it flat again.

My problem with this approach was that both sides are not parallel now, something I have had problems with going right back to my first days in woodwork and metalwork at school. I tried to smooth down the higher side, but knew I was on a looser as that would give me a round side, so I got it as close as I could and hoped that the compression that would be applied would flatten it out. I annealed the washer, this should make it more malleable.
I reassembled it all, after a lot of meticulous cleaning of the injector socket, not at all sure if it would work, but it started first time, with no need for bleeding, and the horrible noise that I had before of the gas escaping had gone. The engine was sounding much better, but closer inspection revealed a small amount of gas still escaping from the injector. the seat that the injector sits in looked like it could do with a polish, but it’s very difficult to access. At least I know how to dismantle it all now, and hopefully when I get the new washer I can try that, however I may get a mechanic in when I reach America/Canada and get that and a few other jobs done on the engine.
While here I managed to get a few more batteries from amazon, they had a limit of 3, and I needed 5, now we have 5 new batteries, and from the pic below it looks like I’m praying, probably that I get more than 3 years out of this batch.

I had actually decided to go for Lithium Ion batteries, but they aren’t available here, so I worked out that these 5 batteries came in at about £450, and if I get a couple of years out of them, hopefully technology will have moved on in those two years and I will be able to save that much on the Lithium Ion batteries. At least we have power for the passage and don’t need to worry about that.
I have started an inspection of the boat now, working from the tip of the bowsprit to the back of the monitor wind steering checking everything, looking for frayed ropes, split wire, loose bolts or anything that might not be 100%. It didn’t take long to find that the block (pulley) that feeds the furling line onto the staysail drum had split and I only had half of the sheave, which itself had sharp edges and a chunk missing. That explains why I was finding the furling to be stiffer than normal recently. Soon I will climb the mast and do the same checks there.
On the way here I ran the watermaker, however it didn’t live up to its name, as it wouldn’t make water, it seemed to have trouble drawing sea water from the hull fitting, but when I put the maker into bypass mode it drew the water, then switching back to normal mode it continued and we made 20 litres of good water in a couple of hours, so that’s good. We also managed to decant some propane gas into the spare cylinder from Ken, our neighbour in Onomichi last week. so we have gas. We have bought a small portable stove and a dozen butane cylinders, as a backup.
So with gas, water, electric and a much improved engine all fixed, the main concerns are gone. I’m also focussing on the human side of things, like warm clothing, bags of chocolate bars etc 😉 and brushing up on my basic weather forecasting skills.
We have found a massive supermarket just a short ride from here, next to the two massive DIY / Hardware stores, so we will provision fully here, tomorrow I go to the Apple store in Osaka to see about a new display for the iPad (Main Nav device at the helm) as I dropped it the other night, and new batteries for my MacBook, which can’t hold a charge for more than an hour now.
If all goes to plan, we will be ready to leave for the big passage in about 5 days time, so then it’s just a case of working our way east, stopping along the way if the weather changes, then off.
Paul Collister.








Also these two boats are towing the bigger boat, and I think it’s more about catching fish than moving a boat, but quite how this works is beyond me, perhaps the big boat has net hanging from it?


The big pipe is used to deliver ice blocks into the hold of the fishing boats.

























The shipping lane near Manila had us negotiating our way around huge cargo and container vessels, but the AIS provided reassurance about collision likelihood. The other benefit of going slowly under sail was the huge saving on the amount of fuel we used, but best of all, no engine means no danger of fishing nets getting caught in the propeller. As darkness fell, more fishing boats appeared and we had to manoeuvre around them. One of the crew on a boat on our starboard side got quite agitated. He shone his torch at our boat in a sweeping motion, then pointed it on the surface of the water. He probably couldn’t tell we had no engine on, but we could only guess he was worried about his nets. It was unnerving not to be sure he wasn’t alerting us about some unseen peril we were heading for, but that’s probably more to do with my overactive imagination 😉 After a dinner of veggie burgers and fried onions in buns (great al fresco fare), we began the night watch. I took the 8 until midnight one and for the first time, felt chilly enough to put a coat on. By the time Paul took over a few hours later, we were almost there. I had intended to stay awake to help with anchoring but I woke to the sound of the anchor being dropped at 3am. Paul had decided we could wait in Benanga Bay and catch up on some sleep so that we could find the marina in daylight.






































We arrived in Yuge for the Setouchi the day before the rally began and had a warm welcome from the organiser, “KC” and some other rally participants who were already there. Above you can see the bridge we passed under as seen from our berth on a small pontoon in the town centre. Yuge Town, is a small affair, you can walk all around it in about 20 minutes, it’s very sleepy and although it has a population of 6000, I only ever saw about five people out at any one point. Below you can see the other rally boats on the pontoon.
We have an Australian couple, Ken and Belinda, on the big cat who are just wrapping up and heading home after spending 5 years touring the Pacific islands. We have Rob, a Canadian who has left the rally early to get up to Kushiro ready to sail over to his home town of Vancouver. We have scrapped plans to leave from there and instead will leave from a lower latitude of 35deg North where we hope to ride the bottom of the depressions heading east. It will be interesting to see who gets there first, however Rob plans to visit Alaska on the way and may well stop off at the Aleutians if he is close and fancies a rest. The other boats are all Japanese crewed, and mostly a lively bunch who enjoy their sake. The big motor boat is owned by a successful businessman who is also a sponsor of the rally. He has invited 6 Australians onboard as well, so they are enjoying a level of luxury we can’t quite match on Sister Midnight, I’m not sure our deck wash spraying into the cockpit well would be as good as their Jacuzzi on the top deck. However at least we don’t have to worry about staff here.

Later that day the students put on a wonderful barbecue for us near the beach and plied us with alcohol and food for several hours.




One thing Nio is famous for is sunsets, and the view from the yacht club was stunning, We’ve seen a few now, but this was good.









































they go so fast and make no wake, but leave a foaming thin spread of white water behind them, like contrails.
The area was becoming more and more industrialised, and looked like a giant version of Ellesmere port/Stanlow oil refinery where I come from.
The air was full of sulphurous smoke from the power station on the shore front. I sailed between wind turbines, and while trying to understand what this huge pylon was that I was sailing towards, about 0.2 nm from shore
I noticed the chart had printed on it OVERHEAD POWER CABLES, crikey I thought, we’re about to be frizzled, or at best, get the electric toaster working for free. The thing was the pylon didn’t seem to have any wires on it, just a mass of aerials, and looking closer to the shore I could see the aforesaid cables going out to some big round structure off to starboard. so false alarm.
It seemed too rough there to stay, the wind was making the sea quite choppy, but I noticed a coastal cargo ship and a tug attached to a barge both at anchor where I had my waypoint. I went beyond them, turned into the wind, slowed the boat and decided it wasn’t that rough at all, we sleep through much worse on night watches, and the forecast was for an improvement anyway, so down went the hook in 10 metres of water. Kathy came to help with the anchoring, she couldn’t believe me that I was going to anchor in such a rough sea, but once the anchor was set, and we went below, shut the hatches and removed our soaking wet-weather gear, everything was just fine. We both slept very well, the new duvet we bought in Fukuoka, along with the three blankets works well, how very different from just a month ago.
then 15 minutes later we were in the inland sea proper. A place I had wanted to see for many years.
Unfortunately during our passage along the strait, the fog and rain returned, this is normal in Japan at this time of year, and so I wasn’t seeing much at all, Kathy maintained AIS watch, and I looked out for small boats from the helm. What disappointed me was the huge amount of fishing buoys/flags we encountered, I presume they have nets strung between them. They are everywhere, and although they don’t present much of a problem to us, due to the underwater shape of our hull with an enclosed propeller, it’s still a fear we might snag one, or have to deal with a fisherman who insists we go around them. Our charts show lots of Fish Havens,
which back home usually is a place where fishing is strictly banned, I presume to allow stocks to recover. Here it seems to be a place where you can fish and string out loads of nets. Interestingly our charts also shows Fish Heavens














































Some nice architecture, disguising the fact that most buildings here on the islands are made of chunky concrete, and tend to be very boxy, designed for earthquakes and tsunamis


From Okinawa we headed up to Miyanoura, a nice port on the island of Yaku-shima, This is a gorgeous island full of wonderful mountains, forests, hot springs, wildlife etc etc. We were running a day late because the previous marina here couldn’t accept us when we planned, due to being closed on Tuesdays! When we arrived we tied up to the only wall we could find, but it was very rough and high, and had a lip that the boat would slip under at low water, so I tied up, took another hit on the cap rail, fortunately on the section I need to replace, but I also lost the bow light (port) when a wave threw us onto the wall. I headed off to explore the port for a better berth and was directed to an inner harbour I hadn’t even seen when we entered by a local fisherman. You can see us on the wall below. We need 6 feet of water to stay afloat, the local fisherman looked worried when I said 2 m water, he shrugged and indicated ‘maybe’. The tide was going to drop by another metre so I took out the lead-line and measured around the boat, on the quay side we had 1.5 metres, on the offshore side we had 3.5 metres, so I figured we might just make it. In the end we didnt touch bottom, but must have been close.
The wall we were now on was much kinder, and you can see below how we rig up the fender boards to protect the boat and fenders



We passed many islands, often uninhabited, but this one stank of sulphur, so I presume it’s still an active volcano.
The marina above is next to a big wheel, which is part of a huge outlet mall.
Kathy ponders the instructions for the fender covers we make from a kit of tubing and cable ties.
Yet new things break at a pace, the sump pump switch for the shower has failed, both of our toothbrush charges packed in, why?