Harken 7320.10 User Manual

ESP JIB REEFING & FURLING

Unit 0, 1

Installation Manual – Intended for specialized personnel or expert users

Preassembly

Safety Precautions/Parts Descriptions 2 – 3
Specifications 3
Parts List 4 – 6
Tools 6
Top Foil 7 - 8
Toggle Deductions/Stay Into Foil 9
Confirm Foil Length 10
Cutting/Drilling Top Foil 11 - 12

Assembly

Foils/Connectors/Halyard Deflector 13 – 17
Halyard Swivel 17
Drum Assembly 17 – 18
Leg Kit with Toggle Assembly 19 – 21
Final 22

5002 05/14

Commissioning

Line to Cockpit/Line on Drum Assembly 23 – 24
Storm Sails 24
Raise Sail 25

Check Halyards 26

Operation

Check Halyards 27
Furl/Reef 28 – 29
Secure Sail 29
Adjust Turnbuckle 30

Maintenance

Clean/Inspect 31
Storage 31

Troubleshoot 32
Product Registration 32
Online Warranty/Product Registration 32
Appendix

Dimensions/Sailmaker's Instructions 33

Please read these instructions carefully before installing, servicing, or operating the equipment.

This manual may be modified without notice. See: www.harken.com/manuals for updated versions.

PLEASE SAVE THESE INSTRUCTIONS

Parts Description

Introduction

This manual gives technical information on installation and service. This information is destined exclusively
for specialized personnel or expert users. Installation, disassembling, and reassembling by personnel who are
not experts may cause serious damage to property or injury to users and those in the vicinity of the product.
If you do not understand an instruction contact Harken.

The user must have appropriate training in order to use this product.
Harken accepts no responsibility for damage or harm caused by not observing the safety requirements and

instructions in this manual. See limited warranty, general warnings, and instructions in www.harken.com/manuals.

Purpose

®

Harken

Jib Reefing and Furling is designed for rolling sails on sailboats to reduce sail size or to completely roll
so wind has little effect on the sail. Use of this product for other than normal sailboat applications is not covered
by the limited warranty.

Safety Precautions

WARNING! This symbol alerts you to potential hazards that may kill or hurt you and others
if you don't follow instructions. The message will tell you how to reduce the
chance of injury.

CAUTION! This symbol alerts you to potential hazards that may hurt you and others if
you do not follow instructions. The message will tell you how to reduce the
chance of injury.

WARNING! Strictly follow all instructions to avoid potential
hazards that may kill or hurt you and others. See www.harken.com/
manuals for general warnings and instructions.

11

10

9

8

9

7

3 4

3a

2

1

3c

6

5

13

12

13

8

3b

Parts Descriptions

1. Leg Kit with Toggle

2. Leg Kit Collar

3. Drum Assembly

a. Neck
b. Guard Posts
c. Spool

2 ESP Unit 0, 1

4. Adjuster Tube Clamp Screws

5. Bow Shackle

6. Adjuster Tube Bushings

7. Adjuster Tube

8. Foil Screws

9. Connector Bushings

10. Feeder

11. Foil (2 m)

12. Connector

13. Connector Wedge

14. Top Foil

15. Halyard Swivel

16. Trim Cap Screws

17. Trim Cap

a. Trim Cap Holes

Preassembly Specifications

16

15

Online Product Registration

17

www.harken.com/FurlingWarranty

5

5

14a

9

13

8

13

12

11

9

9

9

14

105/8"

(271 mm)

Upper measurement
point is to adjuster
tube bushing 6.

7321.22 Medium Leg Kit
Max Turnbuckle Length

1) Leg Kit with Toggle Assembly

b

b

a

a

c

d

c

i

e

d

f

h

g

j

k

Unit 0 Short and Long
Unit 1 Short, Medium, Long

Unit Part Numbers

Unit

0

1

Note: When using a turnbuckle you must use a Medium or Long Leg Kit assembly. *Check max turnbuckle length above.

ESP Unit 0, 1 3

Unit without

Lower Toggle

7320.10 7320.20 — 7320.21

7321.10 7321.20 7321.22* 7321.21

Leg Kit with Toggle

Assembly – Short

Leg Kit with Toggle

Assembly – Medium

g

h

l

Leg Kit with Toggle

Assembly – Long

e

f

Clevis Pin

Ø

5

/16", 3/8"

(8 mm, 9.5 mm)

7

/16", 1/2"

(11, 12.7 mm)

a. Leg Kit Collar Screw
b. Collar
c. Short, Medium or Long Leg
d. Lock Nut
e. Washers
f. Flat Hole in Plate
g. Cotter Pin
h. Spacer
i. Threaded Cross Pin
j. Clevis Pin
k. Jaw/Jaw Toggle
l. Cotter Pin

Wire

Ø

5

/32", 3/16",

(4, 5 mm)

7

/32", 1/4", 9/32", 5/16"

(6, 7, 8 mm)

Sizes

(4.37 mm)

-6, -8, -10

(5.03, 5.72, 6.35 mm)

Rod

-4

Parts List Drum Box

Leg Kit Relative Sizes

L

Short Medium Long

Halyard Swivel

Drum Assembly

Short Leg Kit

DO NOT USE with turnbuckle

Adjuster Tube

Clamp Screws

L

Medium or Long Leg Kit

Required for installation with turnbuckle

Bow Shackles

Drum Box

Description

Halyard swivel
Drum assembly
Bow shackles
Short leg kit with toggle
Medium leg kit with toggle
Long leg kit with toggle
Adjuster tube clamp screws
Blue Loctite

4 ESP Unit 0, 1

®

Part No. Size Length (L) Qty Part No. Size Length (L) Qty

H-58632 — — 1 H-55720 — — 1

7320.10BASE — — 1 7321.10BASE — — 1
2110 6 mm — 3 2110 6 mm — 3

7320.20
— — — 1 7321.22

7320.21

HFS1252 8 mm — 2 HFS1252 8 mm — 3

833 — — 1 833 — 1

Unit 0 Unit 1

5

/16", 3/8" 21/16" (52 mm) 1 7321.207/16", 1/2" 21/8" (53 mm) 1

5

/16", 3/8" 73/16" (183 mm) 1 7321.217/16", 1/2" 111/16" (280 mm) 1

7

/16", 1/2" 61/4" (159 mm) 1

Blue Loctite

®

Parts List Foil Set

Trim Cap

Trim Cap

Screws

Foil Screws

Plastic Connector

Wedges

Feeder

Red Loctite

Adjuster

Tube

®

2 m Foils

Connectors

Connector Bushings

Top Foil

Foil Set

Description

Included
Trim cap
Trim cap screws
Adjuster tube
Foils (2 m)
Top foil
Foil screws
Connectors
Connector bushings
Connector wedges
Feeder
Adjuster Tube Bushing
Red Loctite
Order Separately
Extra Foil (see page 7 - 8)
Extra Connector with bushings

ESP Unit 0, 1 5

®

7320.34.2000 1 7321.34.2000 1

MP-1894 10 MP-1894 14

MP-1975 2 MP-1976 2

Unit 0 Unit 1

Part Qty Part Qty

H-58490 2 H-55976 2
HFS1127 2 HFS1127 2

7320.33 1 7321.33 1

7320.30 4 7321.30 5

HFS384 23 HFS384 31
H-60148 4 H-59907 5
H-58466 10 H-55887 12

H-58461 1 H-55904 1

HFG739 2 HFG739 2

7320.30 1 7321.30 1

7320.31 1 7321.31 1

Adjuster Tube Bushing

Parts List Parts Sold Separately/Tools

Required parts sold separately by Harken:

• Extra foil and connector if required. See pages 7 - 8.

• Harken Short Leg Kit with toggle. Do not use with turnbuckle.

• Harken Medium or Long Leg Kit with toggle. Required for turnbuckle.

• Rod rigging requires Harken rod adapter stud.

• Furling line. To purchase elsewhere, figure length required:

WARNING! Wire that is old
or damaged may break sud­denly, causing an accident.
Headstay condition should
be checked by a professional
rigger before reusing.

Boat length + foot length of largest sail + 6' (1.8 m).

Optional parts, sold separately by Harken:

• Halyard Deflector. Use when halyard exits very close to stay attachment point.

• 7404 Lead Block Kit and one additional 7403 if necessary. Fits 1" (25 mm) stanchions.

Required Parts

Short Leg Kit with Toggle

Do not use with turnbuckle

Unit Part No.

0

7320.20

1

7321.20

Medium Leg Kit with Toggle

Required for turnbuckle

Clevis

Pin Part No.

5

/16, 3/

8

7

/16, 1/

2

7321.22

Long Leg Kit with Toggle

Required for turnbuckle

Clevis

Pin Part No.

— — 7320.21

7

/16, 1/

2

7321.21

Clevis

Pin

5

/16, 3/

7

/16, 1/

8

2

Optional Parts

Halyard Deflector
Unit Part No.

0

7301

1

7302

7404 Lead Block Kit

Includes 3 x 7403; 1 x 7401;

1 x 7402; 1 Horn Cleat

Rod Rigging: Harken Rod Adapter Stud Required

Thread

Rod Size

-4

4.37 mm 7/16" 7420 -4

-6

5.03 mm

-8

5.72 mm

-10

6.35 mm

Size UNF

7

/16" 7421 -6

1

/2" 7422 -8

1

/2" 7423 -10

Part

No.

Furling Line

Unit Part No. Line Ø Length (ft)

0

HFG594 7 mm 55

1

HFG233 7 mm 70

Preassembly Tools Required

1. Hex keys

Unit Size

0, 1

5 mm, 6 mm

2. Socket or open end wrench

Unit Size

0

1

10 mm

16 mm

3. Long tape measure 11. Phillips screwdriver

4. Short tape measure 12. Slotted screwdriver

5. Drill bit – 1/8" (3 mm) 13. Needle-nose pliers

6. Power drill 14. Locking Pliers

7. Hacksaw 15. Center punch

8. Side cutters 16. Hammer

9. Rat-tail file 17. Electric Tape (Use to Mark Foil)

10. Straight edge 18. Vise ( Tape Jaws to Protect Foil)

1

7

6

2

3

4

5

12

12

14

15

16

11

9

13

8

17

18

10

6 ESP Unit 0, 1

Preassembly Top Foil Length

UNIT 0

Measure A and add to this chart
and length chart below

Inches mm

A

B 1.0* 25*

E 24.0 609

F 4.1 104

G

Total A+B+E+F+G

*Add 1" (25 mm) if using a halyard deflector.

Tip: Check to see if the foil fits over
the marine eye. If yes, assemble foils
and lower unit following instructions.
Measure and cut the top foil after
other foils are assembled.

IMPORTANT! Identify top foil before
cutting. Use end with foil screw
holes for connector.

Make sure upper
measurement points
of A and pin-to-pin

Alternate

Measurement

Point

A

are the same.

TOP FOIL LENGTH WORKSHEET

1

2

3

4

To find “D” pick number from chart below that is closest to,
but not greater than total from step 3.

400 inches “D” = 393.7 inches 11,500 mm “D” = 10000 mm

5

Result (Pin-to-Pin – ABEFG)

Inches mm

3 X 78.74 = 236.2
4 X 78.74 = 315.2
5 x 78.74 = 393.7
6 x 78.74 = 472.4

Example–If result from Step 3 is:

Result (C) Top Foil Length

Pin-to-Pin Length

Subtract ABEFG

Subtract D

3 x 2000 = 6000
4 x 2000 = 8000
5 x 2000 = 10000
6 x 2000 = 12000

–

–

Pin

to

Pin

A

B

C

D

Length Check

After completing worksheet above fill in A, C, D, and G below. Add
“A” through “G” to confirm total equals your pin-to-pin measurement.

Length Chart

Dimensions Inches mm

A Center of Pin to Bottom of Terminal
B Bottom of Terminal to Top of Foil
C Top Foil Length ** **
D Number of Foils ________ x 78.74" (2000 mm)
E Adjuster Tube at Just Over Midpoint 24.0 609
F Drum Height 4.1 104
G Top of Leg Kit to Clevis Pin

1.0*

25*

Pin-to-Pin Length

*Add 1" (25 mm) if using a halyard deflector.
**If top foil length is 6.5" to 4" (165 to 100 mm) cut the foil at 6.75" (165 mm). If the top foil

is shorter than 4" (100 mm) do not use a cut top foil. A full length foil will be the top foil.

G Top of Leg Kit to Clevis Pin

Toggle

Part No.

7320.20 5/16 Short Leg Kit

7320.20 3/8 Short Leg Kit

7320.21 5/16 Long Leg Kit

7320.21 3/8 Long Leg Kit

ESP Unit 0 7

Type

Clevis Pin G Distance

in mm in mm

5

/

16

3

/

8

5

/

16

3

/

8

8 3.0 75

9.5 3.0 75
8 8.1 206

9.5 8.1 206

Pin

to

Pin

E

F

G

Preassembly Top Foil Length

UNIT 1

Measure A and add to this chart
and length chart below

Inches mm

A

B 1.1* 28*

E 23.6 600

F 4.9 124

G

Total A+B+E+F+G

*Add 1.1" (28 mm) if using a halyard deflector.

Tip: Check to see if the foil fits over
the marine eye. If yes, assemble foils
and lower unit following instructions.
Measure and cut the top foil after
other foils are assembled.

IMPORTANT! Identify top foil before
cutting. Use end with foil screw
holes for connector.

Make sure upper
measurement points
of A and pin-to-pin

Alternate

Measurement

Point

A

are the same.

TOP FOIL LENGTH WORKSHEET

1

2

3

Result (Pin-to-Pin – ABEFG)

4

To find “D” pick number from chart below that is closest to,
but not greater than total from step 3.

Inches mm

3 X 78.74 = 236.2
4 X 78.74 = 315.0
5 x 78.74 = 393.7
6 x 78.74 = 472.4
7 x 78.74 = 551.2
8 x 78.74 = 629.9

Example–If result from Step 3 is:

500 inches “D” = 472.44 inches 11500 mm “D” = 10000 mm

5

Result (C) Top Foil Length

Pin-to-Pin Length

Subtract ABEFG

Subtract D

3 x 2000 = 6000
4 x 2000 = 8000
5 x 2000 = 10000
6 x 2000 = 12000
7 x 2000 = 14000
8 x 2000 = 16000

–

–

Pin

to

Pin

A

B

C

D

Length Check

After completing worksheet above fill in A, C, D, and G below. Add
“A” through “G” to confirm total equals your pin-to-pin measurement.

Length Chart

Dimensions Inches mm

A Center of Pin to Bottom of Terminal
B Bottom of Terminal to Top of Foil 1.1* 28*
C Top Foil Length ** **
D Number of Foils ________ x 78.74" (2000 mm)
E Adjuster Tube at Just Over Midpoint 23.6 600
F Drum Height 4.9 124
G Top of Leg Kit to Clevis Pin

Pin-to-Pin Length

*Add 1.1" (28 mm) if using a halyard deflector.
**If top foil length is 7.75" to 5" (200 to 125 mm) cut the foil at 7.75" (200 mm). If the top foil
is shorter than 5" (125 mm) do not use a cut top foil. A full length foil will be the top foil.

G Top of Leg Kit to Clevis Pin

Toggle

Part No.

7321.20 7/16 Short Leg Kit

7321.20 1/2 Short Leg Kit

7321.22 7/16 Medium Leg Kit

7322.20 1/2 Medium Leg Kit

7321.21 7/16 Long Leg Kit

7321.21 1/2 Long Leg Kit

8 ESP Unit 1

Type

Clevis Pin G Distance

in mm in mm

7

/

16

1

/

2

7

/

16

1

/

2

7

/

16

1

/

2

11 3.7 93

12.7 3.7 93
11 7.4 188

12.7 7.6 193
11 12.3 313

12.7 12.3 313

Pin

to

Pin

E

F

G

Preassembly Toggle Deductions/Stay Into Foil Options

Rigger supplied: Eye at lower end of stay or turnbuckle to mate with toggle. Use dimensions of Harken toggle
below to build stay to correct length.

Tip: Turnbuckles should be one-half to two-thirds open to allow shortening for new wire stretch and for fine-tuning
mast rake.

Pin-to-Pin Length

Short Leg Kit

with Toggle

Pin-to-Pin Length

Medium or Long Leg Kit

with Toggle

Turnbuckle

with Marine Eye

Leg Kit Toggle

Assembly

Unit

Type Part No. in mm in mm

Short 7320.20 5/16

Long 7320.21 5/16

0

Short 7320.20 3/8

Long 7320.21 3/8

Short 7321.20 7/16

Long 7321.21 7/16

1

Short 7321.20 1/2

Long 7321.21 1/2

Clevis Pin ØPin-to-Pin (P-P)

Length

5

/

16

8 11/1627

3

/810 11/432

7

/16 11 17/1637Medium 7321.22 7/16

1

/213 15/842Medium 7321.22 1/2

Options for Snaking Stay into Foils

1. Swage Stud

2. Marine Eye

3. Wire for Mechanical Terminal

4. Harken Rod Adapter Nosepiece

WARNING! Using a threaded nosepiece with only adhesive at the upper rod eye terminal may result in
headstay system failure. Use Harken rod adapter stud. See www.harken.com/manuals for additional
safety information.

ESP Unit 0, 1 9

Preassembly Confirm Foil Length

Confirm foil length by laying foils alongside stay with turnbuckle components. Pull stay straight. Attach Harken
toggle to bottom of stay. Adjust turnbuckle, if used, so that length of stay with Harken toggle will fit boat. Ideally,
turnbuckle will be one-half to two-thirds open to allow for rig adjustment. Temporarily clamp short or long leg kit
to bottom of unit. Line up:

A. Bottom of full length foil with holes in adjuster tube. Set adjuster tube just above the mid-point of adjustment
range.

B. Holes at lower end of adjust tube with drum assembly holes.
C. Lower holes in leg kit line up with eye in toggle.

Full-Length Foil

Feeder

CBA

Adjuster Tube

Actual adjuster tube will have 12 to 14 adjuster holes. Line up the foil so it is just above the midpoint of adjustment.

Lay all foils out alongside stay and confirm that there will be enough space between the bottom of the marine eye
and the end of the top foil. If necessary, go to lower end, reposition the adjuster tube and lower full length foil
to another position. Confirm that there are two holes for the foil and one for the feeder.

Unit

0

1

Deflector No Deflector

in mm in mm

2 50 1 25

2.1 53 1.1 28

Tip: Check to see if the foil fits over the marine eye. If yes, assemble all foils and lower unit following
instructions. Measure and cut the top foil when all other foils are assembled.

10 ESP Unit 0, 1

Assembly Cutting/Drilling Top Foil

Determine top foil length using charts or by laying foils alongside wire. IMPORTANT! Confirm that you are using the
correct unit size worksheet. Be sure to lay foils, lower unit, and leg kit alongside stay to confirm length before cutting.

Use tape to mark foil. Cut foil to length.

Tool: hacksaw

Trim Cap Holes

Cut off this end with trim cap hole. Hole is

3

only used with full length 78

/4" (2000 mm)

foil as top foil.

Deburr inside edge using a file.

Tool: rat-tail file

Foil screw holes
for connector

Label top foil and identify which end will

Top Foil

be at the top when installed. You will be
drilling each side near the top.

Lay top foil alongside cutoff piece. Use
locking pliers to clamp foils together at
the interior flat surfaces opposite the
sail grooves.

Use a flat metal object (i.e. metal ruler) to
scribe lines on one side of foil. Leave foils
clamped for drilling.

Tools: straight edge, locking pliers

ESP Unit 0, 1 11

Assembly Cutting/Drilling Top Foil

Measure from the end of the foil and put a
mark showing hole distance from top of foil.

Unit

0 .59"

Decimal inFraction

in

19

/32" 15

mm

1 .98" 1" 25

Tool: short tape measure

Use center punch to start hole. Drill one of
two holes for trim cap.

1

Drill Size:

/8" (3.2 mm)

Keeping foils clamped together, flip them to
the other side and repeat the procedure so
there is a hole on each side.

Top Foil

Top Foil

Tools: electric drill, drill bit, center
punch

12 ESP Unit 0, 1

Assembly Foils/Connectors

1. Identify special length top foil with trim
cap holes.

Trim Cap Holes

2. Slide top foil and 2 m foils and
connectors onto wire.

2a. Load connector so bushing cutouts
facing up towards the top of stay.

Note: On top foils under 10" (250 mm),
load top connector so that cutouts for
bushings face down toward
the bottom of stay.

2b. Load onto wire from

Top foil under 10" (250 mm):
Reverse top connector so
bushing cutout is down.

a. Cutout up

top and/or bottom.

Cutout down

b. Top of Stay

b. Top of Stay

3. Make sure that special length top foil
with trim cap holes is at top of stay.

Trim cap holes

ESP Unit 0, 1 13

Assembly Foils/Connectors/Halyard Deflector

4. Put trim cap halves together over wire
and tap in place.

Tool: hammer

5. Secure with trim cap screws.

Tool: Phillips screwdriver

6. If using halyard deflector, install above

®

foil. Use red Loctite

14 ESP Unit 0, 1

on screws.

Red Loctite

Halyard Deflector

®

Assembly Foils/Connectors

7. Hold plastic bushing halves in cutouts
and over wire and insert up into foil.

7a. Make sure foil and connector
screw holes are facing up.

7b. Make sure connector and foil
are aligned.

7c. Hold plastic wedge in place with
thumb as you insert into foil. Align
foil holes with connector screw
holes.

c.

8. Put red Loctite® in foil screw holes and
secure with foil screws.

Tool: slotted screwdriver

a.

b.

ESP Unit 0, 1 15

Assembly Foils/Connectors

9. Join lower part of connector to next foil.

®

Put red Loctite

on screw holes. Secure

with foil screws.

10. Install connector bushings in top of
adjuster tube and insert into 2 m foil.

10a. Make sure foil and adjuster tube
screw holes are facing up.

10b. Make sure adjuster tube and foil
are aligned.

10c. Do not fasten with foil screws at
this time.

16 ESP Unit 0, 1

Adjuster Tube

a.

b.

Assembly Foils/Connectors/Halyard Swivel/Feeder/Drum Assembly

11. Place adjuster tube bushings over wire
and insert into foils until tab snaps into
holes on either side of adjuster tube.
Tap in place.

Tool: hammer

12. Slide halyard swivel onto foil so longer
part is toward top of stay.

13. Slide feeder onto adjuster tube. Do

not secure with screw until later.

Top

Top

ESP Unit 0, 1 17

Assembly Drum Assembly

14. Slide drum assembly onto adjuster tube.

15. Put blue Loctite® on screw holes.
Secure with adjuster tube clamp
screws.

16. Capture jaw/jaw toggle on eye using
threaded crosspin.

When using Harken rod
adapter stud, be sure to use

®

red Loctite

and cotter pins

to lock nosepiece into stud.

18 ESP Unit 0, 1

Assembly Leg Kit with Toggle Assembly

17. Slide one spacer on either side
of jaw/jaw toggle.

18. Secure using cotter pins. Tools: slotted screwdriver, side cutters

19. Slip leg and washers onto
threaded crosspin.

ESP Unit 0, 1 19

Assembly Leg Kit with Toggle Assembly

19a. Make sure flat holes in leg line up with threaded crosspin flats.

Line up flats

19b. Secure using washers and locknuts.

Tools: Socket or Open End Wrench

Unit Size

0, 1

10 mm

If stay length is set, use side cutters
or needlenose pliers to bend cotter
pin to secure turnbuckle.

20. Capture legs in one of the two collars.

Tip: If the legs do not fit collar, loosen
Locknuts at threaded crosspin.

Collar

20 ESP Unit 0, 1

Assembly Leg Kit with Toggle Assembly

21. Slip Leg Kit assembly onto neck of
drum assembly and fit other collar.

22. Secure using Collar Screws.

Tools: Hex Driver

Unit Size

0, 1

5 mm

23. Push the assembled foils up toward the
top of the stay leaving 1" (25) of space
between the top of the deflector or the

Unit

0, 1

Approximate Space

mm in

25 1

trim cap and bottom of marine eye. Align
all three holes at bottom of adjuster tube.
Check to make sure there is space
above halyard deflector or trim cap.

ESP Unit 0, 1 21

Assembly Final

24. Locate nearest group of three screw
holes in adjuster tube, two for the
foil and one for the feeder. Put blue

®

Loctite

in screw holes. Secure adjuster

Blue Loctite

®

tube with foil screws.

Tool: slotted screwdriver

25. Slide feeder to third hole and secure

®

using foil screw and blue Loctite

.

Tool: slotted screwdriver

26. Once on boat, loosen collar screws
enough to rotate opening in drum
assembly towards lead blocks. Put

®

blue Loctite

on screws and tighten.

Tools: Hex Driver

Unit Size

0, 1

22 ESP Unit 0, 1

5 mm

Assembly Line to Cockpit

Mount Lead Blocks

Note: Harken lead blocks referenced below are an available option. Boat manufacturers may have alternate
methods of running furling line to cockpit.

Furling line can be led down either side of boat. If boat is in slip, consider mounting opposite dock.
Remove four screws on stanchion blocks. Clamp blocks to stanchions. See instructions below.

Tip: Start all four screws before tightening.

BOW

7401

FORWARD

STANCHION

BLOCK

OUTBOARD

STANCHION

7403

BLOCK

OUTBOARD
STANCHION

OUTBOARD

STANCHION

7403

BLOCK

7403

BLOCK

7401 Forward Stanchion Block

Position 7401 Forward Stanchion Block so line enters
drum at right angles to headstay and centers vertically
in opening. Install so line is inside stanchion.

Correct block position is critical to even line
spooling and ease of furling.

7403 Outboard Stanchion Blocks

Install 7403 Outboard Stanchion Blocks so line is
outside stanchions.

Number and placement of leads depends on boat
length and number/configuration of stanchions.

7402 Ratchet Stanchion Block

Mount 7402 Ratchet Stanchion Block as farthest-aft
lead to prevent line overrides in drum when unfurling.
Position ratchet block so line turns at least 90°.

Install so line is inside stanchion.

Lead line through block so ratchet makes a clicking
sound when pulling line to furl sail.

Tip: Make sure ratchet switch is in “ON" position.
If there is no clicking sound, lead line through block
in opposite direction.

Lead line to furling line cleat in cockpit.

90°

HCP168 Furling Line Cleat

7402

RATCHET

STANCHION

BLOCK

Install so line is angled as shown. Use #10 (5 mm)
fasteners.

Note: As furling line lead changes, make sure line

Spool Full

(sail unfurled)

doesn't chafe against line guard. Rotate drum
assembly if necessary, see page 22.

STERN

ESP Unit 0, 1 23

Spool Empty

(sail furled)

Commissioning Line on Drum Assembly/Storm Sails

Add Line to Drum Assembly

Run line into drum assembly between guard posts and out hole in lower plate of spool. Exit opening in drum
assembly as shown below. Tie a small overhand knot and pull it up tightly against spool.

IMPORTANT! Do not run line through plastic opening in drum assembly.

Tie a small overhand
knot and pull it up tightly

Guard

Posts

Do not run line through this opening.

Line through hole and opening.

against spool. Spool
must turn freely to furl
and unfurl sail easily.

Wrap Line on Spool

Note location of sun cover on sail. Rotate spool to wrap line.

Sun Cover On Turn Spool

Starboard Clockwise
Port Counterclockwise

Turn spool until there is a tail of line in the cockpit measuring about 1.5 m (5') beyond the cleat or rope clutch.

Sun cover on starboard side: wrap line by
turning clockwise

Sun cover on port side: wrap line by turning
counterclockwise

Storm Sails

Storm sails or heavy air working jibs are necessary when sailing offshore where it is not possible to easily
reach safe harbor.

These sails will generally require pendants to ensure that halyard swivel is properly positioned at top of
headstay. See page 26.

Remember that heavy air working jibs and storm jibs may be reefed and furled like any other sail.

24 ESP Unit 0, 1

Commissioning Raise Sail

WARNING! Sail can become uncontrollable when raising in windy conditions, resulting in loss of footing.
Choose wind conditions to match your experience and ability. If changing sails underway, take all safety
precautions when working on the foredeck. See www.harken.com/manuals General Warnings and
Instructions.

Raise Sail

Head

Choose conditions with little or no wind when raising sail at the dock.
Have bow of boat pointing into the wind.

Feeder

1) Note: Make sure drum assembly is wrapped with line. Shackle
tack of sail to drum. Install shackle so screw pin head is on same
side as sun cover.

2) Secure genoa sheets to clew of sail using bowline knot.
See www.harken.com/knots or consult a knot-tying book.
IMPORTANT! If you are not comfortable tying this or other

secure knots, get help from professional rigger.

Tack

3) Attach genoa halyard to halyard swivel.

4) Carefully guide sail into feeder and then into foil groove.

5) Attach head or pendant at head of sail to halyard swivel.

6) Hoist sail slowly, making sure luff tape does not jam in foil.
IMPORTANT!

Forcing sail can cause luff tape to rip.

Tip: New sails are often stiff and may hang up at feeder during
raising. Do not force sail when it hangs up—lower and remove
twist. Sails "break in" with use and will become easier to raise.

7) Line up front of sail so it is parallel to foil and feeds smoothly when
sail is hoisted.

8) Put moderate tension on the halyard and secure.

9) Check the top area of the furler for interference from halyards.
See “Check Halyards."

10) Practice rolling sail in and out at the dock. See “Furl" and “Unroll Sail."

11) If not sailing right away, make sure sail is furled carefully.
See “Secure Sail."

IMPORTANT! Pay careful attention to “Secure Sail." If leaving the boat,
you must secure sail to prevent damage if wind increases while you
are away.

ESP Unit 0, 1 25

Commissioning Check Halyards

Check Halyards

Once sail is raised, stand back from boat and use binoculars to make sure
there is no interference from halyards.

The jib halyard must exert a slight pull to the rear. This allows the foil to

8–10°

turn while halyard remains stationary.

1. Halyard swivel must be 40 mm (1

1

/2") –150 mm (6") from top of foil.

40–150 mm

2. Halyard must pull slightly to rear (8°–10°).

Halyard Deflector

If the stay attachment is close to the halyard exit the halyard will
not pull to the rear 8° or more and can catch on the top of the foil.
Use halyard deflector to move the halyard away. Check to make
sure there is enough space between the trim cap and the bottom
of the terminal.

Halyard deflector thickness:
Unit Part Thickness

0 7301 25.5 mm (1")
1 7302 29 mm (1

1

/8")

Short Luff Length Sail

If sail luff is too short to position the halyard swivel 40–100 mm
from top of foil assembly, you must add a pendant to the head of sail.

Determine Pendant Length

1. Raise sail, but do not attach tack to drum assembly.

2. Position halyard swivel 40–150 mm from top of foil.

3. Secure halyard.

4. Tie a piece of rope between sail tack and tack shackle.

6. Tension sail.

7. Measure distance from tack shackle to sail tack.
Have a rigger make a pendant to this length using plastic-

coated wire It should be permanently attached to head of sail.

The most serious problem with furling systems occurs when the jib
halyard wraps around the headstay foil. A halyard wrap will keep you
from furling/unfurling and may cause serious damage to the unit and
halyard.

IMPORTANT! A furler with a low halyard swivel may furl correctly in
smooth water/calm conditions, but the halyard will be likely to wrap in
a rough sea.

40–150 mm

Pendant

Head of Sail

WARNING! In severe cases, a halyard wrap can cause loss
of control of boat and/or headstay can break suddenly. Make
sure halyard is clear of top foil before using system.

If halyard wraps, do not force unit to turn. Attempt to open sail by
carefully furling in and out a little at a time. If sail will unfurl, lower it
by releasing jib halyard. If sail will not furl, try to remove one sheet
and run the tied sheet around foil. Use sheet to pull sail around foil
and repeat. This should only be attempted by expert users observing
all safety requirements for going forward.

26 ESP Unit 0, 1

Halyard swivel
is too low

Halyard swivel
is too low

Operation Check Halyards

Halyard Tension

The jib halyard should be firm, but not too tight.

Tip: The foil supports sail along its length so halyard tension is used

Jib Halyard

only to shape sails, not to support them. Use enough halyard tension to
remove some wrinkles along luff of sail. Do not tension halyard enough
to cause vertical wrinkles in luff of sail. Tension to adjust position of
draft in sail to suit sailing conditions. Halyard should be firm but not
tight. If in doubt ease halyard tension. To protect sail, ease halyard
when boat is not in use.

Backstay Adjusters and Halyard Tension

Backstay adjusters allow headstay tension to be varied to change sail shape to match
conditions. They permit a very tight headstay to be eased when boat is not in use. For best
performance, consider adding a backstay adjuster: either a block and tackle, a mechanical
adjuster, or hydraulic adjuster like those offered by Harken.

Remember to keep headstay tight for best performance when furling or reefing.

IMPORTANT! Ease halyard before tensioning backstay adjuster. If not, backstay
adjuster will increase halyard tension and could damage the sail or furling system.

Racing boats often slack the headstay completely when sailing downwind. Check to be
sure that foil does not jam against upper headstay terminal when backstay is released.
It may be necessary to shorten foil slightly to prevent this.

Spinnaker Halyards

Make sure spinnaker halyards are clear of furler.

WARNING! In severe cases, spinnaker
halyards can jam furler causing loss of
control of boat. Make sure all halyards
are clear of top of top foil.

On many boats it will not be possible to attach the
spinnaker halyard to the bow pulpit or it may be
"sucked" into jib when furling.

On some boats the spinnaker halyard lays across the
headstay and will catch on halyard swivel, foils, or
jib halyard.

Boats with external halyards may find it necessary to
flip both ends of spinnaker halyard behind spreaders
to prevent fouling with furling system.

ESP Unit 0, 1 27

Operation Furl

Unroll Sail

Uncleat furling line. Pull sheets to unfurl sail.
IMPORTANT! Keep tension on furling line when unrolling sail so line spools tightly on drum. Use a Harken ratchet block

or keep tension on the line by putting a single wrap of the furling line around a spare winch to provide drag on the line. This
is very important when wind is blowing over 10 knots. When line is tightly spooled on drum it furls in much easier.

Furl

To furl or reef, ease the jib sheets and pull furling line.
In very light breeze, place some tension on jib sheet to insure a tight furl.
In a stronger breeze, you must completely luff sail by totally slacking jib sheets before furling.
The furling line should pull readily. The amount of force required is related to amount of wind, but a unit should never

require use of a winch to furl. If the sail will not furl, or if furling requires a great deal of effort, there is a problem with
system. Consult Troubleshoot on page 32. Do not use a winch to force a system to turn. If you are certain that system
is operating properly you may use a winch to make furling easier.

28 ESP Unit 0, 1

Operation Reef/Secure Sail

Reef

A sail may be partially furled before you resume sailing.
This is known as reefing.

Tip: Place marks on foot of sail for a variety of reefed jib
sizes. Place marks on jib lead track so lead block position
matches reefed jib.

Reef sails to balance boat and reduce heel.

Tip: Reef sails to improve visibility or to slow boat while
sailing in congested areas, or while entering or leaving
harbors.

Secure Sail

When furling the sail completely, make sure sheets and furling line are
secured. Check amount of line on the spool compared to the furled sail

a. 2–3 wraps

before using the system.
A furled sail must have:

a. Two to three wraps of jib sheet wrapped around sail.
b. Two wraps minimum of line wound on spool.
c. Furling line securely cleated.

d. Jibsheets securely wrapped on winch and held in self-tailing jaws.
Furl at dock with tension on sheets to duplicate furling in high wind.
Remember sails furled in light wind and left loosely secured can be a problem

if wind increases.

IMPORTANT! Remove sail from furler if extreme winds are predicted,
especially if boat is left unattended.

2–3 wraps

b.

IMPORTANT! Check all points above—a, b, c, and d—when leaving boat
to avoid damage to furler or boat. A loosely rolled sail can catch wind in
a storm. Sheets or furling lines can loosen as winds increase and allow
furler to unroll.

Be sure mooring lines are not placed across furling line where they may
cause chafe.

IMPORTANT! If no wraps of line are on spool, the line deadend can break
the spool when the boat motors through waves.

If you want to:
Add more wraps of
jibsheet on furled sail.
Add more wraps of line
on spool.

ESP Unit 0, 1 29

Untie jib sheets and keep sail
completely rolled. Secure with
sail tie.

Turn spool to unroll a
couple of wraps of line.

Turn spool to add a
couple of wraps of line.

Retie sheets.

Operation Adjust Turnbuckle

Adjust Turnbuckle

Tools: See page 6 for sizes
Wrench for locknuts
Allen wrench
Slotted screwdriver for foil screws
Sidecutters for cotter pins

Tip: Tape a flat cardboard box or a towel
under the furler to catch any dropped
parts.

Attach halyard to tack shackle, take out
slack and secure.

Remove feeder screw and one foil screw.

While holding foils up, carefully remove
screw and lower foils to drum assembly.

Tip: Have a helper lift foils and hold or
use another halyard while removing last
screw. To use a halyard to hold foils
lifted, tie a rolling hitch to the foils using
another line or use the actual halyard if
suitable. See www.harken.com/knots
for tying resources.

CAUTION! Foils have considerable
weight and can drop and cut hands
if placed underneath. Make sure
foils are securely held up while
adjusting turnbuckle.

Carefully remove plastic collar
and screws.

Do not drop.

Loosen screws and separate legs
from flats on crosspin. Rotate legs
so they are laying on the deck.

IMPORTANT! Parts are easily lost.

Unlock turnbuckle and adjust.

Lock turnbuckle and reassemble
leg kit parts.

Carefully loosen nut enough to move
legs outwards and rotate out
of the way. When reassembling, you
must secure flats on both parts. See
assembly step 19a, (page 20).

30 ESP Unit 0, 1

Maintenance Clean/Inspect/Storage

Clean

Keep unit clean. When you wash boat, flush unit with soap and fresh water.
Occasionally lower sail and flush halyard swivel with soap and fresh water.

Clean unit more thoroughly at least twice a year. First remove line (note

ASSEMBLY

direction on spool) and flush bearings with soap and fresh water.
Clean foils with soap and water. Run scrap of luff tape up foil groove to clean.

WARNING! Parts can wear, loosen, or corrode and can break at

Adjuster Tube
Clamp Screws

load. Periodically inspect items listed below and any others as
necessary. See www.harken.com/manuals General Warnings for
additional safety information.

FOIL

DRUM ASSEMBLY LEG KIT/TOGGLE ASSEMBLY

Inspect

1) Unit for signs of chafe, wear, or damage.

2) Screws on unit for signs of loosening or missing:
Foil Screws – Unroll sail to inspect.
Feeder Screws – Unroll sail to inspect.
Adjuster Tube Clamp Screws

Collar Screws

Collar Screws

3) Foils to make sure they have not dropped into
drum assembly.

Foil Screws

4) Wire for signs of wear, unraveling, or loosening.

5) Locknuts on leg kit for signs of loosening or missing.

Cotter Pin

6) Lower toggle for signs of wear, cracks, or corrosion.

7) Cotter pin at lower toggle to be sure it is securely
splayed as shown.

Feeder Screw

Cotter Pin

Storage – Mast Down

In areas where it freezes, do not store system where water can
accumulate in foils. When water freezes it will rupture aluminum.

Locknuts

Store foils under cover, with grooves facing down or on an angle
so water will run out.

Storage/Transporting

Do not store or transport system with drum assembly extending beyond mast.

Cotter Pin

Lower Toggle

Remove masthead clevis pin and shift furler up so drum assembly can be strapped
securely to mast. Some people remove drum assembly and halyard swivel for storage and transport.

After Storage or Transport

After storing or transporting unit, clean thoroughly, including ball bearings. See instructions above.

ESP Unit 0, 1 31

Troubleshoot Warranty

Problem Probable Cause Solution

Sail will not furl
or unfurl.

Sail will not furl
completely.

Headstay rotates in
jerks or elliptically.

Sail does not stay
furled.

Sail will not go up.

Sail will not raise
completely or luff
will not tension.

Sail will not
come down.

Sun cover rolls up
inside of sail.

Line is wearing on
plastic drum assembly

Jib halyard is wrapping around the headstay
because halyard swivel is too low.

Jib halyard is too tight. Ease jib halyard.
Spare halyard is wrapping in sail as it furls. Secure spare halyards away from furling headstay by flipping them behind spreaders.

Salt or dirt in bearings. Flush bearings with fresh water.
Furling line tangled in drum. Overrides are best prevented by using a 7402 ratchet block as the last furling line lead to

Stop knot catching. Make sure knot is a single overhand and is pushed up inside spool.
Sail full of wind. Luff completely before furling or reefing.
Sail flogging too much. Release a short length of sheet, pull some furling line and repeat.
Jib sheets are not free. Free jib sheets.
Foil out of drum assembly. Reinstall foil in drum assembly and tighten adjuster clamp screws into holes.
No wraps of furling line on spool. Remove sheets from furled sail. Rotate spool to wrap correct amount of line.
Line led through ratchet block backwards. Rerun line.
Halyard swivel installed upside down. Remount swivel correctly.
Insufficient furling line on drum. Remove sheets. Rotate stay, wrapping as much furling line on drum as possible.
Too much line on drum. Adjust amount of line on drum or change position of forward lead block to allow line

Spare halyard catching in sail as it furls. Move halyards away from furling headsail as above.
Insufficient tension on headstay. Tighten headstay and/or backstay to eliminate sag in headstay.

Sail not furled tightly on stay. Maintain drag on sheets while furling.
Furling line not secure. Secure furling line.
Luff tape will not go into groove. Check luff tape for fraying.

Sail catching at feeder. Have someone guide sail into feeder. Purchase prefeeder part no. 947.
Dirt in groove. Clean groove.
Halyard swivel is hitting end stop or trim cap

screws.
Angle between halyard and mast is too sharp

and halyard is pulling too much to the rear.
Halyard is wrapping on headstay. Angle between headstay and halyard is too shallow and must be optimized. See

Furling line is wrapped on spool in wrong direction. Unfurl sail and lower it. Disconnect from furler. Note direction of line wrap on spool.

Line is not led through guide posts. Lead line into drum between guide posts.

See “Check Halyards" regarding optimal halyard swivel height. A wire pendant may be
needed at head of sail to raise halyard swivel to proper height. Use a Halyard Deflector.

Use a Halyard Deflector.

maintain proper drag on line while unfurling.

to roll evenly on drum.

Check luff tape size.

Luff of sail is too long and must be recut. Consult sailmaker.

Luff of sail may be too long. Consult sailmaker.

commissioning "Halyard Wraps."

Pull line from spool and rewind in opposite direction. Connect sail and hoist. See
commissioning section of manual.

Loctite® is a trademark of Henkel AG & Company KGaA

Online Product Registration

www.harken.com/FurlingWarranty

32 ESP Unit 0, 1

Warranty

www.harken.com/manuals

or call, write, email or fax Harken, Inc.,

Pewaukee, WI USA

Appendix Dimensions/Sailmakers's Instructions

Luff Length

Note offsets above and below sail.
If luff of sail is not long enough to put halyard swivel near top of

headstay foil, a pendant must be added (see page 26).

Tack Setback

Note setback for tack shackle and cut the sail accordingly.

B

A

Luff Tape Size - #6 (

6

/32" or 5 mm)

J

K

J - Finished luff tape size: 0.215" (5.5 mm)

6

K - Luff rope size:
L - Max

Ø in sail groove: 0.24" (6 mm)

M - Gap in sail groove: 0.096" (2.4 mm)

/32", 3/16" (4.8 mm)

L

C

D

E

H

F

G

I

A B C D E F Max* F Min* G H I

7320.20 Short Leg Kit – 190 mm

7

/8" 49/16" 13/8" 61/2" 25/8" 377/8" 221/2" 85/16" 77/16" 3"

1

48 mm 116 mm 36 mm (166 mm) (66 mm) (962 mm) (572 mm) (211 mm)

7320.21 Long Leg Kit – 320 mm

7

1

UNIT 0

*"F" Max and Min depend on foil position at adjuster tube.

/8" 49/16" 13/8" 61/2" 25/8" 43" 275/8" 137/16" 129/16" 81/8"

48 mm 116 mm 36 mm (166 mm) (66 mm) (1092 mm) (702 mm) (341 mm)

Luff Tape Length

M

Note feeder height and extend bottom of luff tape downward so it
is below feeder. This will prevent luff tape from catching in feeder
as sail is lowered.

Tack and Head Shackles

Make sure tack and head shackles fit sail rings. Minimum inside
dimensions of standard head and tack shackles are:

Unit A B

0

1

Sun cover

1

1

/16"

27 mm

11/16"

27 mm

1

/2"

3 mm

1

/2"

3 mm

A

B

Sun covers may be installed on either side of sail. Be sure to match
other sails in the customer's inventory.

(190 mm)

(320 mm)

(76 mm)

(206 mm)

A B C D E F Max** F Min** G H I

7321.20 Short Leg Kit – 230 mm

3

/4" 51/8" 13/8" 8" 3" 389/16" 237/16" 97/8" 91/16" 311/16"

2

70 mm 131 mm 34 mm (200 mm) (78 mm) (980 mm) (595 mm) (251 mm)

7321.22 Medium Leg Kit – 325 mm

3

2

/4" 51/8" 13/8" 8" 3" 427/16" 275/16" 133/4" 127/8" 79/16"

70 mm 131 mm 34 mm (200 mm) (78 mm) (1078 mm) (693 mm) (350 mm)

7321.21 Long Leg Kit – 450 mm

UNIT 1

*"F" Max and Min depend on foil position at adjuster tube.

ESP Unit 0, 1 33

3

/4" 51/8" 13/8" 8" 3" 471/4" 321/8" 189/16" 1711/16" 125/16"

2

70 mm 131 mm 34 mm (200 mm) (78 mm) (1200 mm) (815 mm) (471 mm)

(230 mm)

(325 mm)

(450 mm)

(93 mm)

(191 mm)

(313 mm)

N15W24983 Bluemound Rd, Pewaukee, WI 53072 USA

Telephone: [phone] • Fax: [phone]

Web: www.harken.com • Email: [e-mail]

1B Green Street, Brookvale, N.S.W. 2100, Australia

Telephone: [phone] • Fax: [phone]

Web: harken.com.au • Email: [e-mail]

ZA Port des Minimes, BP 3064, 17032 La Rochelle Cedex 1, France

Telephone: [phone] • Fax: [phone]

Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy
Telephone: [phone] • Fax: [phone]

158 Beaumont Street, Westhaven, P.O. Box 90689, Victoria St. West, Auckland 1142, New Zealand

Telephone: [phone] • Fax: [phone]

ul. Rydygiera 8, budynek 3A, lokal 101, I pi

Main Office and Harken Brandstore: Västmannagatan 81B

Telephone: [phone] • Fax: [phone]

Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand

Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England

Telephone: [phone] • Fax: [phone]

Web: harken.co.uk • Email: [e-mail]

Corporate Headquarters

Harken Australia Pty, Ltd.

Harken France

Web: harken.fr • Email: [e-mail]

Harken Italy S.p.A.

Web: harken.it • Email: [e-mail]

Harken New Zealand, Ltd.

Web: harken.co.nz • Email: [e-mail]

Harken Polska SP ZOO

Tel: [phone] • Fax: [phone]

Web: harken.pl • Email: [e-mail]

Harken Sweden AB

SE-113 26 Stockholm Sweden

Web: harken.se • Email: [e-mail]

Harken UK, Ltd.

ętro, 01-793 Warszawa, Poland

Please visit: http://www.harken.com/locator.aspx

to locate Harken dealers and distributors

Printed in USA 5002 05/14