Offshore - Master Maintenance List

Maintaining Boats for Offshore Sailing - Master List

On most boats, the offshore safety gear gets stowed in the bottom of the most inaccessible locker and rarely sees the light of day. Before going offshore, you literally "turn the boat upside down" as you stow harbor gear and get out the offshore safety gear. In addition to getting out the offshore gear, a prudent mariner will inspect critical systems and perform routine maintenance before departing.

These checklists will lead you through the process of preparing the boat and gear for an offshore voyage. Most of the items on this checklist are done at dockside. There is a separate checklist for performing operational tests during an offshore sea trial. There is also a separate checklist for items to equip your boat for offshore voyaging.

Give yourself 2 to 3 weeks of time to run through this checklist; don't start it 24 hours before you depart. Focus on safety items first, then on making the boat sail well. Finish up with comfort and convenience items.

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Offshore Inspection & Maintenance

	Item	Link to Detail
Abandon Ship Gear
	Make sure that the life raft has been serviced as the manufacturer recommends. Most recommend a 12 month inspection/repack schedule.	Repack cost calculator Winslow Raft Repack Process
	Take ditch bag out of storage and place it where it's accessible for immediate use. Review the contents of the ditch bag and make sure nothing has been "borrowed" for other purposes. Replace expired items as necessary.	Detailed list of ditch bag contents.
	Make sure that the weakest crew member can lift the ditch bag and life raft.
	Check operation of EPIRG/GPIRB per manufacturers instructions. Replace battery if necessary .	EPIRB test procedure
Anchoring Gear
	Move excess anchor chain from the chain locker back to the bilge to reduce weight up forward.
	As you move the chain, consider turning it end-for-end if you haven't done so in several years.
Collision Avoidance
	Check to see that binoculars are in good working order with clean lenses.
	Check operation of radar on a sunny day when you can see near, middle and distant targets.
	Check operation of deck light(s).
	Check mountings on radar reflector(s) for chafe and make sure they're secure enough to withstand high winds. Make sure that radar reflectors are not chafing sails.
	Verify that running lights are operational. Remove covers, clean out moisture and corrosion, grease contacts and bulb bases with dielectric grease and reassemble.
	Charge up spotlight (cordless).
	Verify that tri-color masthead light (if installed) is operational. Remove cover, clean out moisture, grease contacts and bulb bases with dielectric grease and reassemble.
	Foghorn is operational. Electric horn is preferred, but a handheld air horn is acceptable (with spare can of air). Manual foghorns work.
	Verify that white anti-collision flares (optional) are in service date.	Pains Wessex recall notice
Cooking
	Refrigeration system works properly; cools off adequately
	All stove burners work properly
	Make sure drain in propane bottle locker is not clogged by flushing it out with a hose.
	Inspect flexible hose connecting stove to propane supply. Replace if worn or cracked.
	If you have a pressure gauge on your propane system, perform a leak test by pressuring the system, then turning off the valve at the bottle. The system shold hold pressure fr 24 hours.
	Test operation of propane sniffer system. System should shut off solenoid when a small butane lighter (unlit) is held near the sensor for a few seconds. Vacuum dust off of the sensor periodically when you vacuum the floor.
Communication
Single Side Band (SSB)
	Radio Check - Single Side Band radio is operational; check ability to receive weather broadcasts and talk on cruiser nets and frequencies you will be using.
	Ships Station license for SSB is up to date
	Verify that list of frequencies and times is posted next to SSB	List
	Verify that emergency broadcast instructions card is posted next to SSB	Quick Ref Card
VHF Radio
	Handheld VHF is charged. Spare battery pack is charged or has fresh batteries in it. Radio check shows handheld to be functional.
	VHF radio check; radio is operational and can send/receive messages to a station at least 8 miles distant.
	DSC equipped VHF (optional) - Radio displays lat/lon, indicating a good connection to the GPS.
Crew Safety
	Inspect jacklines for wear/chafe. Replace if necessary
	Inspect PFD/harnesses for wear. If using inflatable's, verify that CO2 cylinder is armed. Strobe and whistle are attached to PFD. Inflatable PFD's should be inflated annually and left for 48 hours to verify that they're not leaking.
	Inspect harnesses for wear/chafe. Replace if necessary
	Replace batteries in personal strobes if more than 1 year old.
Damage Control & Jury Rigging Repairs
	Verify that basic materials for repairs (e.g. plywood, wire, fiberglass, etc.) have not been used for other projects. Check the shelf-life of adhesives and sealants and replace if they are outdated. (Old adhesives won't set up properly)	Detailed list
	Verify that tools for removing the damaged rig have not been "borrowed" for other uses.	Damage control tool kit list
	Collision mat
Dewatering
	Take emergency pump, hoses and handle out of storage. Put them in an easily accessible place. Test the pump, then rinse with fresh water.
	Fill the bilge with fresh water, then test operation of main bilge pump, noting how long it takes to empty the bilge.
	Clean bilge of any debris that may jam the bilge pump; clean the bilge pump screen ; clear limber holes
	Operate all seacocks to make sure they move easily. Place a tapered, softwood plug in a zip-loc bag next to each through-hull.
	Flush out cockpit drains with a garden hose. Plug the cockpit drains and fill with a garden hose. See how long it takes to empty the cockpit. Consider installing larger drains is it takes more than 2 minutes or so to drain.
	Verify that buckets (at least 2) are ready for immediate use
	Check operation of high-water alarm in bilge - set for 6" above bilge pump trigger level .
Drinking Water
	Clean/flush sediment out of water tank(s)
	Clean screen on pump guards / filters
	Fresh water pressure pump operates. Pump doesn't cycle when all faucets are turned off (i.e. no slow leaks in system)
	Water level indicator or gauge operates; shows level increasing as tank is filled up
Electrical
	Perform a draw-down test on the batteries to determine their current amp-hour capacity.	Draw-down test procedure
	Check battery fluid level and top off if necessary.
	Inspect battery terminals for corrosion; clean as necessary and apply dielectric grease. Check connections to make sure they are tight.
	Inspect bonding system (green wires) to make sure engine, tanks, rigging, etc. are connected together.
	Inspect back of circuit breaker panel for any loose wiring, chafe or other signs of damage.
Fire Fighting
	Verify that fire extinguishers are in cockpit, galley and each sleeping cabin and are easily accessible.
	Check pressure gauges on all fire extinguishers. Replace those that show signs of leakage.
	Turn dri-chem extinguishers upside down and shake vigorously to loosen up power inside.
	Verify that smoke hood / breathing apparatus is readily accessible by the companionway.
Fire Prevention
	Inspect containers of solvents (e.g. acetone) for any signs of rust or leakage. Discard any damaged containers
	Never store dinghy gas tank below decks or in a cockpit locker.
	Check shore power cords for evidence of corrosion, arcing or other heat damage
First Aid
	Review items in first aid kit. Replace outdated items as necessary. Replenish items that have been used.	List of supplies
	Review items in the advanced first aid kit (trauma kit). Replace outdated items as necessary. Replenish items that have been used.	List of supplies
Fix Broken Gear
	Review inventory of spare parts on board. Replace spares/supplies that have been used.	Spare parts checklist
	Review inventory of tools. Replace lost, broken or worn tools.	Recommended tools checklist
Generate Electricity
	Verify that alternate energy sources (wind / solar) are charging the batteries. Inspect connections and wiring for chafe.
	Perform routine service maintenance on the genset (if installed)	Diesel engine maint checklists
	Shoreside battery charger is correctly charging all house batteries and engine start battery (if installed).
	Inverter works; provides 110v electricity. An appliance, such as a vacuum cleaner, that fits within the rated output of the inverter operates properly.
Head
	Verify that head is in good working order; lubricate by slowly flushing down 1/2 cup of any vegetable oil.
	If head hoses are getting clogged with mineral deposits (e.g. head is getting hard to pump) they can be cleared with a solution of muriatic acid.
Heavy Weather Sailing
	Jib roller - flush out bearings with fresh water. Examine reefing line for chafe. Check rigging and make sure that cotter pins or lock rings are in place.
	Mainsail reefing - flush out blocks with fresh water. Examine reef lines for chafe. Check rigging and make sure that cotter pins or lock rings are in place.
	Storm sails - hoist storm sails to make sure that sheet leads are fair and that any modifications to the boat have not made it impossible to use the storm sails.
Hull / Underwater Maintenance & Inspection
	Send a diver down to clean the bottom, rudder and prop. This can add 1/2 to 1 knot to your speed (12 to 24 miles per day)
	Check raw water intake - clear any barnacles or debris
	Check cutlass bearing for wear by attempting to wiggle the propshaft - more than 1/8" of play is too worn

Knockdown Preparation
	Batteries are secured by heavy duty straps or other restraints
	Drawers and locker doors have positive catch latches
	Floorboards are latched down with screws or latches
	Glass items are stowed in lockers or other secure locations
	Items on shelves are restrained with bungee cords or nets
Masthead Maintenance
	Bring all of the tools and parts you'll need so you make one trip up the mast
	Inspect VHF antenna
	Inspect all standing rigging fittings; examine swages for cracks.
	Check spreader bases to make sure they're fastened securely to the mast.
	Examine jib furling gear to make sure there's no chafe, especially on the short piece of the jib halyard extending from the masthead sheave to the head of the jib.
	Change bulbs in masthead light, anchor light, tricolor deck light(s) (if more than one year since it was last done. Save old bulbs for spares.
	Examine mainsail track; clean and lubricate with a dry silicone spray if necessary.
	Inspect masthead sheaves for halyards to see if they are damaged. Plastic sheaves are particularly vulnerable to long-term UV damage.
MOB Gear
	Check battery in MOB pole strobe - replace if more than 1 year old. Write date on battery with a magic marker. Check strobe for proper operation and water tight integrity by placing it in the water.
	Check MOB pole for ease of deployment. Polypropylene line on MOB may need replacement (annually) if damaged by UV light.
	Check batteries in PFD strobes - replace if more than 1 year old. Check strobes for proper operation.
	Lifesling or similar MOB retrieval device is in good shape and ready for immediate deployment. Line will run free with no tangling.
	Type IV throwable PFD's (2) in cockpit are in good shape, not damaged from being used as cushions.
	Dye marker packets (4) are ready for immediate use in cockpit.
	Helmsman's pouch containing strobe, dye marker and flares is ready for immediate use. Flares are in service date.
Motoring
Engine / Drive Train Maintenance
	Inspect engine and perform recommended maintenance	Diesel maintenance checklist
Fuel System
	Inspect tank, hoses, connections for any signs of leaks
	Clean fuel tank(s) of any sludge or debris. "Polish" the diesel fuel by cycling it through a 2 micron filter.
	Change primary and secondary fuel filters. Verify that a supply of filters is on hand for replacements.
	Practice the sequence of steps necessary to bleed the fuel system. Try this out at the dock before you have to do it offshore. Make sure you have the proper tools, especially metric wrenches.
Navigation
Manual Navigation
	Binoculars are in good working order with clean lenses.
	Calculator works and has fresh batteries.
	Celestial Navigation Equipment (optional) - Sextant checked for index error. Have the sextant professionally aligned if it has been dropped or abused. Check chronometer or watch for accuracy. Check to see that the nautical almanac is up to date and that you have enough sight-reduction work sheets
	Compass - Ship's compass checked for accuracy and has been adjusted if necessary.
	Compass - Hand-held compass has been checked for accuracy
	Cruising guide books for the area(s) you're visiting are up to date.
	Depth sounder operates and has been checked for accuracy with a leadline.
	Leadline is stowed in a place where it can be quickly reached.
	Make sure that have up to date paper charts for the area you sail in and for the harbors you'll likely visit.	NOAA Chart Index
	Tide tables (e.g. Eldridge Almanac for East Coast) are up to date.
	Tools for paper-based navigation - pencils, eraser, dividers, protractor, parallel rules or rolling rule, calculator are stowed neatly in the nav station.
Electronic Navigation
	Electronic charts/chips: Check to see if you have both sailing and harbor charts for your intended areas. Check dates of publication on your charts vs. a current chart catalog. Replace charts that are out of date.
	Electronic charting tools (optional) - Chartplotter and chart chips (or computer and charting software) are operating properly. User's Guide is readily available for crew to study
	GPS's - Primary GPS operates. Optional: primary GPS correctly feeds data signal to the NMEA devices (radio, radar, autopilot, etc.)
	GPS's - Backup GPS (usually handheld) has fresh batteries and operates.
	Inverter (if using a 110v item like a laptop for navigation). Bring a spare inverter as well
	Radar (if installed) is working properly.
	Speed and distance log (knotmeter). Check the log versus a known distance on a still day with no current.
	Check for proper operation of wind meter / instrumentation
Paperwork / Foreign Ports / Return to US
	All crew have current passports , and visas if necessary.
	US reentry sticker is current
	If traveling to a foreign port, type up a crew list with pertinent information	Crew list form
Sails and Rigging
Running Rigging Inspection & Maintenance
	Turn halyards and sheets end-for-end if you haven't done so for a year or so. You'll get more life out of these lines and they'll work better. If sheets are old and stiff with salt, soak them in a bucket of fresh water with some fabric softenener overnight.
	All winches operate smoothly. Disassemble and lubricate any that don't.
	Whisker pole fittings move freely. Trigger ends on whisker pole move freely.
	Jib sheets should be tied with bowlines with the tail end seized to the standing part. Don't use a clove hitch and a single sheet - it's a single point of failure.

Standing Rigging Inspection & Maintenance
	Inspect all fittings to make sure cotter pins and/or seizing wire is in place
	Make sure that clevis pins are of the proper diameter - should be the same size as the hole, not smaller in diameter.
	Inspect all wire-end terminals for evidence of cracks or other damage. Replace any suspect fittings.
	Adjust tension on stays and shrouds according to manufacturers specs. You'll repeat this process after your sea trial / shakedown cruise.
	Inspect chain plate bedding after you've tuned the rig. Rebed if necessary or if bedding is more than 3 years old.
	Check mast boot for any signs of leakage. Replace or repair mast boot as necessary to prevent leaks while sailing offshore.
	Verify proper operation of all equipment that had wires reconnected when the mast was stepped. (e.g. lights, VHF, radar, wind instruments)
	Note: do NOT tape turnbuckles as many people do. The tape traps moisture and causes corrosion.
Salt Water Leaks
	Search for possible leaks by closing up the boat and spraying all areas of the deck with a high-pressure water hose. Isolate and fix any leaks you find.
	Inspect the mast boot and renew if necessary
	Check stanchion bases for loose bolts - they are a primary source of leaks
	Rebed any loose deck fittings or hardware to prevent water leaks.	How-to Article
Self Steering
	Hydraulic autopilot: fluid reservoir is full; hydraulic pump, ram and lines show no evidence of leaking
	Check the heading displayed on the autopilot vs. the ships compass. Adjust the autopilot electronic compass according to the manufacturer's directions.
Ship's Papers / Regulatory Items
State Licensing
	State registration numbers on boat
	Certificate of state registration for boat
	Certificate of state registration for dinghy
Federal Documentation
	Vessel's documentation number is permanently attached to the boat
	Federal documentation certificate
	FCC Ship's Station radio license
Environmental Compliance
	Oil Placard posted in prominent location
	Trash placard posted in prominent location
	Trash plan document	Sample form
Other
	Ship's Log
	Copy of "Navigation Rules / International-Inland" aka "rules of the road " (Publication # COOMDTINST M16672.2D)

Steering
	Inspect all steering hardware: linkages, cables, sheaves, etc. Look for evidence of wear or damage. Replace any suspect parts.
	Inspect rudder to make sure it's not damaged. Line up rudder with keel to see if rudder stock is bent or misaligned.
	Look for evidence of water intrusion into the rudder as soon as the boat is pulled out of the water. Any drips at the bottom of the rudder may indicate water has migrated into the core of the rudder
	Make sure emergency tiller/equip is readily accessible. Practice using the emergency tiller before an emergency.
	Grease the rudder shaft bearing (if it is a type that accepts grease)

Standing Watch
	Check dates on the flares in the MOB pouch that the helmsman wears.
Storm Preparation
	Drogue, rode and bridle have been neatly repacked if they've been moved or used.
	Emergency tiller or backup steering system is readily available if needed.
	Storm sails with pre-attached sheets are readily available if needed.
	Sea anchor and rode have been neatly repacked if they've been moved or used.
USCG Required Items - Subject to inspection during a boarding
	Horn or other sound producing device is operational
	MSD - head cannot discharge directly overboard in US waters.
	See also items under Ships Papers
	Running lights are operational
	At least one PFD for each crew and one throwable are on board.
	Visual distress signals are up to date (at least 3)

Warmth - Keep the Crew Warm
	Check operation of heat source. Check operation of carbon monoxide detector.
Weather
	SSB radio is successfully receiving weather reports ; practice listening to these reports for a week or two before your departure.
	Navtex receiver (optional) operates properly and receives offshore forecasts.
	Calibrate/check barometer by comparing your readings to weather reports from VHF weather channels. Perform this over a series of days to see that high/low readings are reliable.

Links to Outside Resources

Click here for a list of links to how to articles that will help you with your maintenance tasks.

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