Monday, July23, 2018

Harken Jib. Reefing Furling. System

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This instruction manual is an essential
part of your new furling system Keep it on
board and refer to it to insure troublefree
operation of your furling system
Your new jib reefing and furling system is
the most advanced furling system on the
market It incorporates a Duratron plastic ball
bearing system that requires only an oc
casional cleaning and light lubrication and will
never rust or gall Separate swivels for the tack
and head make the system ideal for reefing
the sail while keeping the sail shape efficient
ead Shackle
A turnbuckle built into the system allows ad
justment Installation as you will see in this
manual is very simple
The finest combination of materials
engineering and production procedures will in
sure years of troublefree use with little main
tenance but some care and service is essen
tial Please read this manual carefully to
Torque Tube
familiarize yourself with the unit and its
operation and Plastic Locking
Split Cylinder
Threaded Stud
Tack Washer
Restraining Washer
Halyard Swiw
Special Connecto
Luff Foil
Actual Size
8riV connector connector
Luff Tape
Sails for this system require a No 6632
A ong
o t t o mconnector
luff tape to fit in the luff extrusion grooves
Tack and Head Shackles
Tack and head shackles are 111617mm
wide and 1 1238mm long inside dimen
ah sions Additional information available
Foil Extrusion upon request
The Harken system is guaranteed for a period of five years against defects in materials
or workmanship Defective items may be returned to the point of purchase or to Harken
and Harken shall at its option replace or repair such product Return of defective products
should be accompanied by a letter giving name address date of purchase a s well as an
explanation of the defect or malfunction and the conditions under which the product was
being used
The warranty does not apply to or include any part of the system or the complete
system if it was improperly installed or maintained or used under load conditions ex
ceeding the rating or wire size or its equivalent rod size as published in the Harken
catalog or in this manual Swage fitting and lower threaded stud guaranteed for two years
IMPRO PER INSTALLATION INCLUDES faulty swaging or improper assembly of Nor
semanor or drilling out roll pins not threading lower
toggle and upper stud fittings far enough into the body not securing properly with locking
mechanisms not using toggles at both ends of stay improper halyard leads failure to use
a pennant at head of sail if needed or any other procedure that is not a normal and prudent
rigging procedure
IMPROPER MAINTENANCE INCLUDES failure to clean salt and dirt out of bearings
failurs to spray or apply light lubrication periodically failure to check locking mechanisms
and wire and foils for damage failure to check stainless swages and threaded rods for
crevice or stress corrosion expecially in tropical waters
IMPROPER OPERATION INCLUDES forcing the drum to turn if it or the halyard swivel is
stuck by winching or other means not using a ratchet block or other means to put drag on
furling line putting too much or too little halyard tension on the sail and unseamanship like
use of the system under adverse conditions
This warranty is in lieu of all other implied express and statutory guarantees and in no
I event shall Harken be liable for special incidential or consequential damages The laws of
each state may vary giving you additional rights and some of the above limitations or ex
clusions may not apply to you
Locking 271
Drum assembly which includes drum drum body with bearings tack swivel and threaded toggle notched locking plate and locking nut
Furling line
Feeder assembly with screws
Bag foil connector screws 1 bag foil connector swivel with two tube assembly which includes torque tube foil
clamp clamp screws and prefeeder on wire pennant
Bag of three torque tube screws
Bottom foil extrusion 26 660mm long
7 21311 main foil extrusions Number of foils vary with
length of your headstay A standard kit contains 8 foils
TOPfoil trim cap Typical wire headstay with marine eye and swage
stud showing connectors top foil trim cap and special
Top foil extrusion Length varies with length of headstay top connector strung on wire
Note this foil is cut from one of the 7 213m foils
and if you have elected to cut your own foil to length
this top foil will be top connector
I I I280mm bottom connector piece I Chromed bronze locking collar with plastic split
9 229mm regular connector pieces Number cylinder
varies with length of kit I octiteg 242 blue
contains 7 connectors Note connectors will be 1 Loctite 271 red
strung on wire unless you have elected to do 1 Instant Adhesive Referred to as u e r o n d e r
this yourself
Every furling unit is provided with
one of these threaded studs From
left to right Norseman stud extra
long swage stud for use with existing
headstay wire
and Navtec adapter stud
Extrusion connectors and foils
You will need the following tools to assemble
your jib furling system If you have elected to cut your own foils to
length you will also need
1 Screwdriver
1 Hacksaw
1 1 114 wrench
or large adjustable wrench
I Fine round file
Sandpaper or emery cloth
If you have elected to use a Norseman8 or Sta
1 Large Vice Gripstype pliers
Loc fitting you will also need
Electrical tape
I Sharp cutter designed for I x 19 wire
P a e rtowels or clean rags
Norsemanand may be used with Unit 2 A special locking collar is required with
these fittings and can be provided by your jib furling distributor
Special assembly instructions are provided for use with Norsemanand and are ship
ped with special locking collars
The assembly instrucfions are clearly marked with a stop sign to indicate when the special instructions
for Norsemanand should be referred to
i A
PL r
L 33zL
y j j j T
I 1 a id z 7 r
lr if
l r b j s
Navtec 12 and 7 7 rod may be used with Unit 2 A special adaptor stud and locking collar are required
when using Unit 2 with a Navtecrod headstay Special instructions are shipped with the Navtec adaptor
package which is available from your jib furling distributor
The assembly instructions are clearly marked wilh a stop sign
to indicate when the special instructions
for should be referred to
Use a halyard to rig a secure temporary headstay to support your mast during installation of your jib
furling system Do not attach this temporary headstay t o the stemhead fitting of your boat as this may in
terfere with installation of the furling unit
Select a flat work area that is longer than the stay and free from gravel dirt and sand
the proper number of connectors strung on the wire in the proper order and the top foil cut to length and
Section A of this manual pages 69 explains
a Measuring headstay length
Measuring and cutting headstay wires
s Placing the correct number of connectors on the wire in sequence
Cutting the top foil to length
ob Special foil length If you have chosen to complete these steps yourself carefully read and follow these instructions with the basic assembly
procedures which begir on page 10 of this manual
If your jib reefing and furling system has been supplied ready to install you may proceed to the instructions on page 10
All headstays are measured from the center of the pin
holding the headstay to the masthead toggle to the center of
the pin holding the headstay assembly to the te
This measurement should include all turnbuckles and
toggles at the lower end but should not include the
masthead toggle
All headstays must be secured to a toggle fitting at the
masthead Your jib furling system is provided with an on the lower stud fitting An additional toggle is not at the lower fitting but
may be fitted if the stay is
too short or if it is desirable to mount the drum higher off the
deck than normal say to provide more clearance for an an
chor fitting
Should an additional toggle be fitted to the headstay be
sure to subtract the pin to pin length of the toggle from the
overall length of the LONG STUD
The extra long swage stud is designed to compensate for length lost when an existing turnbuckle is cut
off of an existing headstay The extra long threaded stud may be used whenever cutting off the will shorten your headstay less than 26660mm Shortening
a wire this amount will limit turn
buckle adjustment
To use the extra long swage stud subtract 24610mm from your overall headstay length and cut the
wire at that point Measure from the center of the hole in the marine eye at the top of your headstay wire
This measurement will result in a turnbuckle which is one half to two thirds open
It is important to use the swage stud provided by Harken t o insure that the length is correct when this
formula is used Be sure that the stud is properly swaged by a reputable rigger
1 481l1491O m 2 7 787rnrn
42 1 12827rn 49 1 14961 rn 56 1 17094111 63 1 19228rn 29 838mrn
42 3 12878rn 49 3 15011rn 56 3 1714511 63 3 19279rn 211 889rnrn
42 5 12929rn 49 5 15
0 62111 56 5 171 96rn 63 5 19329rn 3 1 940rnrn
42 7 12979rn 497 15113rn 56 7 17247rn 63 7 19380rn 3 3 991rnrn
42 9 13030rn 49 9 15164rn 56 9 172971 63 9 19431rn 3 5 1041m
631lW1 9482rn 3 7 1092rn
43 1 13132rn 50 1 1526511 57 1 17399m 64 1 19533rn 3 9 1143rn
4 3 3 13183rn 50 3 15316rn 57 3 17450rn 64 3 19583rn 311 1194rn
43 5 13233rn 50 5 15367rn 57 5 17501 rn 64 5 19634rn 4 1 1245m
43 7 13284rn 50 7 15418rn 57 7 17551 m 64 7 19685rn 4 3 1295111
43 9 13335111 50 9 15469rn 57 9 17662111 64 9 19736rn 4 5 1346rn
431 ln13386rn 4 T1397rn
44 1 13437rn 51 1 15570rn 58 1 17704rnj 65 1 19837rn 4 9 1448rn
44 3 1348711 51 3 15621rn 58 3 177551 65 3 17
7 551
1 1 4 111499rn
44 5 13538rn 51 5 15672rn 58 5 17805m 65 5 19939rn 5 1 1549rn
44 7 13589rn 5g 7 15723rn 58 7 17856rnj 65 7 19990rn 5 3 1600rn
44 9 13640rn 51 9 15773rn 58 9 17907rn 65 9 20041rn 5 5 1651m
5 7 17021
45 1 13741 rn 52 1 15875rn 59 1 18009rn 66 1 20142rn 5 9 1753rn
45 3 13792rn 52 3 159261 59 3 180591 66 3 20193rn 45 5 13843rn 52 5 15977m 59 5 181 1O m 66 5
20244rn 6 1 1 8 5 4
45 7 13894rn 52 7 16027rn 597 18161rn 66 7 20295111 6 3 1905rn
45 9 1394511 52 9 16078rn 59 9 1821 2rn 66 9 20345rn 6 5 1956111
6 7 2007rn
46 1 14046m 53 1 16180rn 60 1 18313m 67 1 20447m 6 9 2057m
46 3 14097rn 53 3 16231 rn 60 3 18364m 67 3 20498m 6 Cut the top foil to length from one of the 7 213m foil
extrusions packaged with your standard Unit 2 If your top foil
length is shown as zero seepage 8 On some occasions an assembled foil may be slightly too long If this is the case
simplytrirn the excess length with a hacksaw and deburr thecut Becareful not to irito the bearing
The length of your jib furling system is matched to your boats headstay length by adjusting the number of
7213m foil extrusions used and by cutting the top foil to length
Consult Charts B and C to determine
The number of full length 7213m foil extrusions used in your system
e The length to which to cut your top foil extrusion
After determining the length of your top foil extrusion use a sharp hacksaw to cut this piece from a
7213m extrusion
Using emery cloth sandpaper or a fine file rough up the surface of the top 125mm of the top foil to
provide a grip for the adhesive used to secure the top foil trim cap to the foil
Carefully deburr the inside of the foil cavity and cean all shavings from the inside of the foil Failure to
deburr or to clean the inside of the top foil may cause it to seize on a connector when it is being Your jib furling system is designed to ride
over the swage
fitting at the top of your headstay It is important that the foils
be cut to the correct length to insure that your foil does ex
tend well up onto the swage fitting and it is also critical that
the foils be clamped in a fully raised position See assembly stage 7 on page 13 of the in
struction manual
In some rare cases it is not possible for the foil to ride
over the shank of the upper swage fitting These cases in
e Headstays with no upper swage fitting because the
um e r wire terminal is a fitting
headstas Most headstays have a Typical masthead detail showing foil riding over shank
of swage stud and within 251mmJ of the pin in the up
shank that the foil can ride on per marine eye
B Other headstays without swage fittings such as those with wire splices
In cases where the topfoi1 cannot ride over the swage fitting you may need to cut the top foil shorter to
adjust the length The figures in Chart B are based on the upper end of the foil riding 251mm from the cen
ter of the pin in the upper marine eye If the foil cannot ride that close shorten the top foil by the from the 251mm point to where it can ride
If your foil cannot ride over the swage shank it should be shortened as little as possible In these cases it
may be possible for the halyard swivel to ride off of the foil and use of an optional head swivel end stop
should be considered Boats using a short foil may also require a block on the front of the mast to minimize
the possibility of halyards wrapping on the foil while furling
If your top foil length is shown as zero your unit does not use a special top foil In this case the top 7 213 m
foil extrusion is treated as your top foil and the special top connector fits into this extrusion
If your fop foil length b shown as zero and is followed by a number in a shaded box eg 0 a f f i
your unit does not use a special top foil In this case the top T213 m foil extrusion is treated as your top foil and
the special top connector fits into this extrusion and a new bottom foil is cut to the length shown ie 30 762 mm
from a 7 213 ml foil extrusion and is used in place of the 2 610 mm bottom foil section This 7 213 rn foil is in
addition to the number of T213 m foils shown inchart C
How Manv Foils and Connectors Strinaina Connectors
How Many Connectors
Use the chart at left to determine the proper
number of 9 229 mm connectors for your
Every unit uses one 11 280 mm bottom
connector in addition to the number of
9 229 mm connectors shown at left
How Many Foils
Use the chart at left to determine the proper
number of 7 213 m foils for your headstay
The variable length top or bottom foil is cut fr
one of the 7 213 m foils and is used in
addition to the number of foils shown at left
Stringing the headstay has been cut to lerigth but before the lower terminal is attached the proper number of
connectors must be placed on the headstay in the correct order
H Every unit uses a top foil trim cap
H Every unit uses a number of 9 229 mm connec
tors which varies according to the length of the
headstay and is determined by consulting the chart
Every unit uses one 11 280 mm bottom
Slide the trim cap onto the stay so that tlie open end faces
Slide the proper number of 9 229 mm connectors onto
the the 11 280 mm bottom connector onto the headstay so that it is closest to the bottom of
the the wire swaged by a reputable 1 1990 Unit 2 9
Norseman StaLok and Navtec Refer to special Stretch the headstay wire out straight The end with the threaded stud is the bottom Slide the
foil trim cap to the top of the wire
has two beads of silicone rubber and should be strung on your
headstay wire closest to the marine eye at the top of the wire
Secure the regular connectors loosely against the threaded
stud by placing several wraps of tape around the above the the special top connector to the top of the wire
Check the top foil extrusion Which has been cut to lengfh for burrs or shavings at the cut end Clean
and deburr as needed Note do not confuse the top foil with the 26660mm boffom foil the top foil extrusion screw holes down over the threaded stud and
connectors to the top of the coat the surface of the special top connector with Loctite 271 red Push this top connector into
the tor of the tor foil
Use a screwdriver to push the special top connector into the
top foil so that it is completely recessed inside the top foil 5 or
6 127 or 152mm The special top connector must be
recessed sufficiently to permit the top foil to ride over the shank
of the marine eye at the top of the headstay wire Check the
depth of the recess by comparing the depth to the length of the
swage shank with your screwdriver the top I 25mm of the top foil extrusion with Loctite
Super Bonder 495 and press the top foil trim cap onto the top of
the top foil
Remove the tape holding the connectors against the threaded stud and free one connector from
the group
Retape the wire to restrain the remaining connectors loosely against the threaded stud
Slide the free connector to the top of the stay Liberally coat the top half of the connector with Loctite 271
Place the plastic connector wedge in an indentation on the front of the connector with the wedged side
Push the connector into the top foil using care to keep the
plastic wedge in place in the slight indentation in the
connector Continue to push the connector into the foil until
the threaded screw holes in the connector line up with the
holes in the foil extrusion
Liberally coat two foil connector screws with Loctite
271 red and screw them into the connector until
they are tight
Select a 7 213m foil extrusion and carefully check for burrs metal shavings or dirt on the inside surface
i Remember that the best way to see dirt is to look down the foil while pointing it towards a light source
Slide the 7 213m foil extrusion onto the stay over the threaded stud and connectors and up to the top
foil piece
Liberally coat the half of the connector which is sticking out of the top foil extrusion with Loctite 277 red
Place the plastic connector wedge in the indentation on the front of the connector with the wedged
side up
Push the 7 213m foil over the connector until the holes
align Be sure that the plastic connector wedge slides into the d
Liberally coat two foil extrusion screws with Loctite
271 red insert into the connector and tighten
firmly with a UNIT2 FEE190 11
S9OP REFER TO this process until all of the 9 229mm connectors have been used
Slide the I I 280mm connector up to the bottom foil extrusion Liberally coat the top 4 112 I 14mm of
the long bottom connector with Loctite 271 red Place one foil connector wedge in the the foil
Push the long bottom connector into the foil until the screw holes align with the holes in the foil coat the foil connector screws with Loctite 271
red insert into the connector hole and with a coat the bottom 4 112 1 14mm of the long bottom connector with Loctite 271 red Place one
foil connector wedge in the indentation nearest the foil
Push the 26 660mm bottom foil extrusion onto the wire and over the long bottom connector until the
screw holes align with the holes in the foil extrusion When properly assembled a 2 318 60mm gap will
be leff between the bottom foil and the first 7 213m foil
Clean excess Loctite 271 from all joints with rags or paper towels Be sure to clean excess Loctite from the
grooves and from the exposed connector between the 26 660mm bottom foil extrusion and the first 7
213m foil REFER TO Slide halyard swivel onto the foil with the small
shackle up Do not place the halyard swivel on
the foils upside down Slide the halyard swivel
up past the 2 318 60mm gap in the foils
Remove the screw from the stainless steel feeder casting Carefully open the feeder position it over the
2 318 60mm gap in the foils with the thick end up and secure it over the gap with the screw Use
Loctite 242 blue on the screw The feeder uses a loose hinge and care must be taken not to drop
one of the parts
Slide the torque tube assembly onto the foil prefeeder end up
and clamp it to the foil near the feeder where it will be out of
the way during the remaining REFER TO INSTRUCTIONS I
Slip the plastic locking split cylinder into the locking collar split end first
Slip the chromed bronze locking collar onto the stay over the
threaded stud with the threaded end of the collar down
Thread the drum assembly onto the threaded stud just until
the colored mark on the threads is completely engaged in the
turnbuckle body and does not show
Please be aware that the coloring on the threads is only provided for your convenience during It may wear off and the only positive means of
insuring that you have proper engagement of the threads
onto the turnbuckle is to measure the exposed threads At no time should more than 2 114 57mm of
thread be exposed at eifher the fop or boffom of the turnbuckle
Check to see that the bottom stud with toggle is engaged in the drum just to the point where the colored
mark on the side of the threads does not show
Clean foils and grooves of any dirt or excess Loctite which may have accumulated during assembly
Carefully check to see that all of the screws are set flush with the surface of the foil Excess Loctite should
be cleaned before it cures
Raise the headstay and secure it to the masthead toggle and stemhead chainplate Use care while raising
the furling system to support the headstay to prevent bending or kinking of the foils
UNIT 2 FEE190 13
olored portion of the threads or more than 2 7457mm of thread is exposed at
either the top or the bottom of the drum assembly the headstay is too short and a toggle MUST
be added t o the system
Align the opening in the stainless steel drum basket with the proposed furling line lead
You may wish to install the furling line lead blocks at this time to insure that your alignment is accurate For
the proper alignment procedure consult the section describing leading the furling line to the cockpit on page
15 of the instruction manual
Slide the notched locking plate up the lower stud until the notches
slip over the two pins which protrude from the bottom of the It may be necessary to turn the drum slightly to align the pins
with the notches
Slip the restraining washer up the stud until it rests against the not
ched locking plate
Thread the locking nut up the lower stud and tighten it firmly against
the restraining washer with a 1 114 wrench
Norseman StaLoc and Nav
t e c refer t o S p e c i a l In
Thread the chromed bronze locking collar down onto the top of the
drum assembly Tighten firmly with a 1 118 wrench while holding the
swage stud with a Vise Gripstype pliers Place a rag under the pliers
to prevent damage to the stud
Tightening the chromed bronze locking
collar while holding threaded swage stud
with Vise Grips Note use of rag to protect
Slide the torque tube down the stay and secure to
the drum assembly using the three screws provided
use Loctitem Securing torque tube to the drum assem
bly using three screws provided
Lift the foil extrusions up the wire so that the top o f the foil rides over the swage fitting
at the top of the headstay wire and is within 2 of the center of the pin securing the wire
to the masthead toggle
Failure t o raise the foils wlll cause considerable friction in furling Raising the foils
too high may prevent the folls from rotating
Tighten the torque tube clamp tightly to secure the foils in the raised position
Securing foils to torque tube while holding
in raised position Foils must b e raised to
correct height or difficulty in furling will
result A
To insure proper operation of your jib furling system it is important that the
halyard swivel be within the top 6152mm of the foil when the sail is fully
raised and adjusted to normal sailing tension This will allow ample room for
additional luff tensioning to control sail shape while minimizing the possibility
that the jib halyard will wrap around the headstay while furling
It may be necessary to add a wire pennant to the top of short hoist sails to
insure that the halyard swivel reaches the proper hoist height
It is also important that the halyard pull
slightly to the rear to prevent wraps In some
cases the jib halyard will lay nearly parallel to
the headstay when the halyard swivel is fully
raised and as a result will not exert sufficient
pull to the rear to prevent halyard wraps In
these cases it may be necessary t o add a
block to the front of the mast t o hold the
halyard t o the rear to prevent wraps Consult
your dealer or an experienced rigger for ad
vice on how this can best be done on your
boat Note Too extreme a pull to the rear will
the use of wi
cause difficulty in raising sails and could
pennants to insu cause damage to the foils
proper halya
swivel height
This halyard swivel is too low and jib
halyard has wrapped around foil during
urling Halyard wraps will prevent furling
and may cause serious damage
b i
Ic i
A i
r A
r 2
j l
L if
1 Remove the sail from the headstay and the furling line from the leads
2 Carefully loosen the torque tube clamp and lower the foils
3 Remove the screws holding the torque tube to the drum assembly slide the tube up the stay and clamp
lightly near the feeder
4 Loosen the bottom locking nut and washers and top chromed bronze locking collar
5 Adjust headstay tension by turning the drum assembly and realign the opening in the drum basket with
the furling line lead
6 Check to be sure that no more than 2 1457mm of thread is exposed at either the top or bottom or the
7 Tighten the top locking collar and bottom locking plate
8 Resecure the torque tube to the drum assembly
9 Lift thefoils being sure that the foil slips onto the shank of the top swage as described in assembly stage
7 on page 13 Secure the foils in the raised position
Relead the furling line
L Jb secured to halyard swrvel and
7 j JLA
i Jil
being fed into for1 groove through the
prefeeder and the feeder
1 Shackle the tack of the sail to the tack swivel located on the top of the
drum assembly
2 Secure the genoa sheets to the clew of the sail
3 Attach the genoa halyard to the top shackle on the halyard swivel
4 Feed the luff tape at the head of the sail through the prefeeder and through
the feeder into either groove in the foil
5 Attach the head of the sail to the shackle on the bottom of the halyard
6 Be sure that the sail is flaked near the headstay andis not tangled
7 Hoist the sail
Attach furling line to drum as shown in sketch by passing one end up
and out of the hole in the drum top Secure line by tying a stopper knot in
the end of the line
Furling lines should be led to the cockpit through a series of
Harken ball bearing big bullet blocks Big bullet blocks should be
mounted on I37 eyestraps which can be screwed to the deck or
gunwales On a few boats it may be possible to secure the bullet
blocks to the toerail On other boats it will be possible to use 061
stanchion mount bases or secure to stanchion bases with
shackles but on most boats this will result in the furling line not
being held close enough to the rail
centers the line
To attach furling line to drum
pass line up out of hole and The furling line may be led down either side of the boat
secure by tying a stopper knot Position the forward lead block SO
in the line
that the furling line enters the drum at right angles to the
headstay and is centered vertically in the opening of the
drum basket Moving the forward lead block forward or aft
will center the line vertically in the opening
Care must be taken when aligning the opening in the
basket horizontally to see that the furling line leads properly
at all times Note that the angle at which the line exits the
basket changes as the amount of line on the drum changes
When furling line is wrapped on the drum in a clockwise
direction the opening will generally appear off center to star
board The opposite is true for wraps Be
sure to check the lead for chafe with varying amounts of line
Furling line lead changes on the drum before tightening the locking devices
The aftermost lead block MUST be a 019 little Hexarat
on the drum changes chet block This block insures proper drag during unfurling
to prevent line overrides in the drum
The line wrapped on the drum so that
the drum rotates in a clockwise direction when a sail is being
furled Improper rotation may result in your sails ultraviolet
protector cover being wrapped inside the furl See the
Guide on page 78 for a solution should this
The aftmost lead block must be a
Intermediate lead blocks Harken bullets hold Harken 019 little Hexaratchet to
the line near the gunwale The number and provide proper line drag while furling
placement of these leads depends on Your boat This of9block should be positioned to
lengfh and lead furling line to a cleat conveniently
located in the cockpit
Position of forward lead block a Harken
bullet block is critical as a proper lead
prevents line chafe
Typical Furling Line
Lead f Cdckgit
it will be difficult to furl the sail In ex
tremely light air it may be necessary t o p l a c e a very slight drag on the jib sheets to insure a neat furl
2 Pull the furling line The line should pull readily If the sail will not furl or if furling requires a great deal of ef
fort there is a problem with the system Please consult the Guide DO MOT USE A WINCH
3 Cleat the furling line and secure the sheets
REEFING A SAIL Reefing is the same as furling but stop furling when the sail is reefed to the desired
Your jib reefing and furling system is provided with holes in the drum and basket which may be aligned
and used to lock your system when furled or reefed Simply drop a pin or shackle through these holes or
secure with a piece of line Locking the system will prevent accidental unfurling of your reefed or furled
7 Remove the sail from the headstay and
the furling line from the leads and drum
2 Remove the sail feeder from the stay
lower the halyard swivel to the top of the
drum assembly and remount the sail
3 Slack your backstay rig a secure tern
porary headstay to support the mast
and remove the lower end of the head
stay from the boat
4Remove the screws holding the
Sliding the stainless steel drum
stainless steel basket to the drum and basket off of stay over toggle
slide the basket off of the stay over the
lower toggle fitting
5 Remove the screws holding the drum to
the turnbuckle body and slide the drum
off of the stay over the lower toggle fit
6 Reattach the headstay to the boat and
tune the rig Secure the tack of the sail
directly to the tack fitting on the boat
and attach halyards directly to the sails
tom locking plate or unthread the bottom toggle stud
4 Using care to prevent the wire from slippngup into the foils
remove the bronze locking collaf plastic locking cone torque Lower end of headstay with drum and halyard
tube and halyard swivel swivel removed for more serious racing
5 Slide the torque tube back onto the foils slip the bronze locking collar and plastic locking cone onto the
threaded stud and thread the drum assembly onto the stud to its proper position as previously marked
6 Firmly tighten the top locking collar to the d n f m assembly raise the foils and secure in this raised
position by tightening the torque tube clamp
UNIT 2 FEB190 17
The Hardkote anodized Teflon im
pregnated aluminum stainless steel silicon
bronze and Duratron used in the construction
of your jib furling system require very little
The bearings are open and a heavy rain
will flush most salf and dirt from the races An
occasional rinse with a freshwater hose
should be sufficient to purge ariy remaining
salt or dirt from the bearings
It is strongly recommended that a light
lubricant such as WD 40 or LPSI be sprayed
directly into the bearing races of the halyard
swivel and the tack swivel where you can see
the bearings There are red plastic lubrication
points on the halyard swivel tack swiveand
on the main bearing assembly The latter are
exposed by removing the furling drum The
small plastic tube usually packaged with
these lubricants will fit into these lubrication
points Lubrication sprayed down into the
torque tube will also find its way into the main
bearing assembly
It is very important to thoroughly examine the swage fittings and lower toggle stud for signs of fatigue or
stress corrosion on a regular basis Carefully inspect each fitting for hairline cracks or signs of corrosion This
is especially important in tropical climates Replace any fitting which shows signs of cracking or corrosion at
The strength of your headstay assembly depends upon sufficient engagement of the turnbuckle threads
into the body Both the top threaded stud and the lower toggle stud were colored to aid in initial assembly but
this dye may wear off and the only positive check of proper thread engagement is to measure the exposed
threads At no time should more than 2 1457mm of thread be exposed at either the top or bottom of the
drum Problem Probable Cause Solution
Piece was not secured at stud and was Check for missing connector inside of foil extrusions
carried up inside of a foil
I Too many connectors Too many strung on wire Leave extra connector loose inside last 7273m foil I
I Foil will not slip past threaded stud Dirt in foil or on stud Clean foil and stud
Swage stud is bent Return stay to distributor Do not attempt to straighten
Connector will not fit into foil extrusions Dirt in foil or on connector Clean connector and foil
Warning color shows on threads at Stay is too short Add a toggle to the headstay to increase length Do not sail
turnbuckle when rig is tuned or more with colored portion or more than 25Tmm of threads ex
than 2 1457mm of thread is exposed posed
at the to or bottom of the turnbuckle
Problem Probable Cause
Sail will not furl Jib halyard is wrapping around headsta y See installa tion instructions regarding optimal
because angle between mast and angle and halyard swivel height A wire pennant may be
halyard is too shallow or halyard swivel needed at the head of the sail to raise the halyard swivel to
is too low the proper height
Foils riding on locking collar Raise foils per Assembly Stage 7
Foils too high binding on swage eye Lower until 251mm from pin or until clear
Spare halyard is wrapping in sail as it Secure spare halyards away from the furling headstay
furls possibly by flipping halyard behind spreaders
I Furling line is tangled in drum Overrides are best prevented by using a 01 9
Little Hexarat
chet block as the last furling line lead to maintain proper
drag on line while unfurling
Salt or dirt in bearings Flush bearings with fresh water and lubricate
Jib sheets are not free Free jib sheets
No wraps of furling line on drum Remove sheets Rotate stay to wrap as
much furling line on the drum as possible
Line through 019 backwards Rerun line
Sail will not furl completely Insufficient furling line on drum Add line to drum as above
Halvard is catchino in sail as it furls
1 Headstay rotates in jerks or elliptically Insufficient tension on headstay
aail does not furl neatly Insufficient drag on sheets while furling Maintain drag on sheets while furling especially in
Sail does not stay furled Sail not furled tightly on stay Maintain drag on sheets while furling
Furling line not secure Secure furling line
Sail will not go up Luff tape will not go into groove Check luff tape for fraying
Check luff tape size
Sail catching at prefeeder Flake sail more loosely on deck
Dirt in groove Clean grooves
Sail will not raise c o m l e t e or
l luff will Halyard swivel is hitting end stop Luff of sail is too long and must be recut
not tension Angle between halyard and mast is too Halyardmust be routed from point higher on the
mast This
sharp and halyard is pulling too much to may require that any halyard turning blocks aloft be
the rear replaced Consult your dealer for advice
Sail will not come down Halyard is wrapped on headstay Angle between headstay and halyard is too shallow and
must be optimized per the installation Halyard swivel off foil Foil too
short or too low
Ultraviolet cover rolls up inside of sail Furling line is wrapped on drum in wrong Remove sheets Pull line to remove all furling line
direction drum Turn stay to rewind line on drum in opposite direction
Notebasket alignment may need to be adjusted

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