Page 1
Carbo Racing Foil
Instruction Manual
Unit 0, 1, 2, 3
WARNING!: Strictly follow all instructions to avoid
an accident, damage to your vessel, personal injury
or death. See www.harken.com for additional safety
information.
Page 2
2 Unit 0, 1, 2, 3 Carbo Racing Foil 05/04/09
Required
Phillips Head Screwdriver
Flat Bladed Screwdriver
Hacksaw
Pliers
Tape Measure
Drill with 3/16" (5mm) bit
or 1/4" (6mm) Unit 3 only
Recommended
Heat Gun for
cool weather
Sail Specifications
Unit Luff Tape
#0 #5–5/32" (4mm)
#1 #6–3/16" (5mm)
#2 #6–3/16" (5mm)
#3 #6–3/16 (5 mm)
& #7–7/32" (6mm)
Pre-Assembly
Tools
Recommended height above deck:
Feeder: 42"(110cm).
Prefeeder: 30" (76cm).
Sail luff tape
must be 6-10"
(15-25cm)
below feeder
when sail is
raised.
6-10"
(15-25cm)
Description Unit 0 Unit 1 Unit 2 Unit 3
Extrusion H-37931B H-36315B H-37820B H-413 60
Trim Cap H-37932B H-34427B H-37833B H-41337
Feeder H-37934C H-34394C H-37838C H-41315
Spacer
Tub e
Upper H-37935A H-34433A H-37879A H- 41339
Lower H-37936A H-34432A H-37880A H-41338
Prefeeder 7006 7006 7006 7006
PV C Tape HCP1748 HC P174 8 HC P174 8 H CP1748
Chafe Guard 7000.30 7001.30 7002.30 —
Unit 0 Foil Length Max. Headstay
7000.9 m 29'6" (9m) 32' 9" (10m)
7000.12 m 39' 4" (12m) 42' 8" (13 m)
7000.15 m 49' 2" (15m) 52' 6"(16m)
Unit 1 Foil Length Max. Headstay
7001.12 m 39'4" (12m) 42' 8" (13m)
70 01.16 m 52' 6" (16m) 55' 9" (17 m)
7001.20 m 65' 7" (20m) 6 8' 11"(2 1m)
Unit 2 Foil Length Max. Headstay
7002.16 m 52'6" (16m) 5 6' 6 " (1 7.2 m)
7002.20 m 65'7" (20m) 69'7" (21.1m)
7002.24 m 78'9" (24m) 82'9" (25.2m)
Unit 3 Foil Length Max. Headstay
7003.24 m 78' 8-1/2" (24 m) 82' 8" (25.2 m)
7003.28 m 91' 10" (28 m) 95' 9" (29.2 m)
Max Unit 0 Unit 1 Unit 2 Unit 3
Wire
1/4" (6mm) 5/16" (8mm) 3/ 8" (10mm) 7/ 16" (11mm)
Rod
-10 (6.35mm) -17 (8.38mm) -25 (10.31mm) -30 (11.1mm)
Size Check
Fasteners
Unit 0
HFS1048 6-32x.375 Trusshead Screw
HFS1049 6-32x.375 Barrel Nut
HFS699 6-32x.625 Flathead Screw
Unit 1
HFS1048 6-32x.375 Trusshead Screw
HFS1049 6-32x.375 Barrel Nut
HFS1047
6-32x.75 Flathead Screw
Unit 2
HFS1094 6-32x.5 Trusshead Screw
HFS1049 6-32x.375 Barrel Nut
HFS1093 6-32x.875 Flathead Screw
Unit 3
HFS347 8-32x.5 Trusshead Screw
HF S1139 8-32x.5 Barrel Nut
HFS1138 8x32x1 Flathead Screw
Parts
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03-2008 Unit 0, 1, 2, 3 Carbo Racing Foil 3
Pre-Assembly
1. Lay Out Foil
Unroll foil and let it relax for a day or
so before installing.
2. Feeder Height
Measure 42" (110 cm) from deck and
mark stay.
3. Foil Length
Attach tape measure to halyard.
Measure exposed portion of stay from
underside of terminal aloft to mark
made in step 2. Deduct 5" (127 mm)
for upper spacer tube.
4. Cutting Foil
Mark foil using measurement from
step 3. CUT TOP END ONLY. Don't cut
bottom of foil with Harken® labels and
feeder hole.
4. Continued
Cut upper end of foil with hacksaw.
5. Trim Cap Hole
Place foil so side grooves face up.
Slip cap on foil so split end is over
groove and large hole faces up.
Tip: Trim cap holes are different
diameters. Make sure 3/16" (5 mm)
drill bit fits through hole and foil
side grooves face up.
Squeeze cap with pliers. Keep drill
straight and drill a 3/16" (5 mm) hole
part way through foil. Remove cap
and finish drilling. Check fit of trim
cap, screw and barrel nut. Adjust
hole as needed.
Make sure headstay is taut on boat
or stretched taut on ground before
installation.
Page 4
Splay 5" (127 mm) upper spacer tube
with flat bladed screwdriver, slip onto
stay and tape.
1. Upper Spacer Tube
Important: Tape full length of
spacer tube.
2. Foil Start
Identify top of foil. Side groove
will be on starboard.
Tip: In cool
weather, use
a heat gun
to warm foil.
Tip: Foil installs easier if excess is
held out to starboard side of boat.
3. Trim Cap
Place trim cap on foil so slot is aft,
with large hole on starboard. Squeeze
together with pliers. Put blue Loctite®
in barrel nut. Install two-piece screw
and barrel nut with Phillips screwdriver.
4 Unit 0, 1, 2, 3 Carbo Racing Foil 02-2010
4. Foil
Snap foil into place by pulling aft with
one hand, while sliding foil up with
the other. Use heat gun.
Tip: Use liquid soap to lubricate
headstay and foil.
Splay foil with screwdriver and pull
onto stay. Once foil is started, stop
to install trim cap.
Installation
Do not spray McLube to lubricate
headstay and foil. See Maintenance
on Page 8 for details.
Page 5
Installation
03-2008 Unit 0, 1, 2, 3 Carbo Racing Foil 5
5. Feeder
Slip feeder into place and firmly push
upwards.
Coat screw with blue Loctite® and
tighten. If screw does not thread,
check alignment.
6. Bottom Tube
Push foil up as far as it will go.
Measure length from feeder to bottom
of exposed stay, for lower spacer
tube length.
Cut, splay, and snap tube into place.
Tape full length of lower spacer tube.
7. Prefeeder
Measure 12" (300mm) below feeder
and lash prefeeder to tube.
Tape prefeeder in place.
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6 Unit 0, 1, 2, 3 Carbo Racing Foil 03-2009
Installation
Halyard Lead
Halyard must be parallel to stay. If halyard pulls at an aft angle, it will pull out
luff tape and damage foil grooves.
Quieting Bare Foil in Strong Wind
While motoring or moored in high wind, bare foil oscillates, creating an annoying
noise. To prevent this, wrap jib halyard around foil four to six times, secure to
deck fitting (foreguy bail), and hand tension at winch.
Raising Sail
Use prefeeder when raising sail. Raise sail completely
and tension halyard before sheeting. Sheeting sail too
soon can damage luff tape and foil.
Sail Misfeed
To prepare for the rare occasion when a sail misfeeds,
some grand prix sailors drill a small exit port (shown
at right). If sail jams on hoist, lower until misfeed runs
down into gap, then re-hoist.
Using Carbo Racing Foil
Chafe Guard
Before installing, sail with spinnaker a few times to
produce a few wear marks. Chose location to cover
marks. Squeeze bead of silicone sealant up length of each
inside edge of guard. Press in place. Use supplied PVC
tape to hold guard securely for 24-hours before using.
Page 7
01-2010 Unit 0, 1, 2, 3 Carbo Racing Foil 7
Troubleshooting—Use
Problem Probable Cause Solution
Bare foil is noisy in wind Needs to be stabilized
Wrap jib halyard around foil 4-6 times,
secure to deck and hand tension at winch.
Sail luff tape comes out of
groove
Luff tape too small
Check to see if luff tape is #6, 3/16" (5 mm)
in diameter.
Top of luff tape does not
feed into feeder or catches
Luff tape is frayed
Trim loose material with hot knife. Smooth
with sandpaper.
Bottom of luff tape pulls
out of plastic foil
Luff tape is cut too
short
Install longer luff tape so it protrudes
6" (15cm) below feeder.
Top of luff tape pulls out
of plastic foil
Halyard angles too far
aft
Change location of halyard sheave
so halyard is parallel to stay.
Top of sail has pulled out
of foil above feeder
Halyard has yanked luff
tape out of foil
Remove feeder to re-feed. Drill hole in foil
just above feeder to re-feed future pull-outs.
Sail will not raise or lower
easily, too much friction
Halyard sheave
is jammed
Check sheave bearings
and sideload bearings.
Dirt or other material in
foil grooves.
Make a cleaner out of piece of luff tape and
grommets.
Luff tape is too large
Install correct luff tape. System 7000 uses
#5, 5/32" (4mm); System 7001, 7002 uses
#6, 3/16" (5mm).
Luff tape is damaged or
dirty
Clean sail luff tapes and lubricate with thin
film of McLube
®
. Spray on shore, away from
Carbo Racing Foil and boat. Replace or repair
as necessary.
Luff tape needs
lubrication
Clean sail luff tapes and lubricate with thin
film of McLube
®
. Spray on shore, away from
Carbo Racing Foil and boat. Let McLube dry
completely before feeding sail into foil.
McLube or other toluene- or acetone-based
lubricants must not be sprayed near foil. Use
McLube on sails but not on Carbo Foil.
Luff tape damaged after
raising sail
Load put on sail before
it is raised
Raise sail and tension halyard before
sheeting
Troubleshooting—Installation
Problem Probable Cause Solution
Foil is difficult to
start onto stay
Foil is stiff from cold Heat foil to improve flexibility
Too much friction from
stay
Check diameter of stay. See specifications on
Page 2.
Foil is curved when unrolled Foil has taken set Unroll foil and let it relax in warm conditions
Trim cap does not fit
Trim cap is incorrectly
aligned
Place cap on foil with split side on groove
side and large hole on starboard
Hole drilled incorrectly Examine hole and ream out so it fits
Difficult to snap
foil on stay
Stay is too loose
Tension stay, if on ground stretch
taut between two solid attachments
Needs more upward
movement
Pull foil in and up. Push down on foil if
installing on land.
Feeder does not fit
Feeder is on
upside down
Remove feeder and install so side groove is
on starboard
Page 8
1251 East Wisconsin Avenue, Pewaukee, Wisconsin 53072-3755 USA
Telephone: (262) 691-3320 • Fax: (262) 691-3008
Web: www.harken.com • Email: harken@harken.com
8 Printed in USA 4364/02/01/10
Harken equipment requires minimal maintenance, but some is required to give the
best service and to comply with Harken's limited warranty.
It is important to keep equipment clean by frequently flushing with fresh water. In
corrosive atmospheres, stainless parts may show discoloration around holes, rivets
and screws. This is not serious and may be removed with a fine abrasive.
Sails—Keep sail luff clean and inspect for signs of damage and fraying and repair
if necessary.
The Carbo foil material is slippery. If more lubrication is required, spray a thin
coat of McLube® on sail luff tapes away from Carbo Racing Foil and boat deck.
Be sure to let sail dry before feeding sail into foil.
Maintenance
For additional safety, maintenance and warranty information see www.harken.com or
the Harken
®
catalog.
Warranty
CAUTION!: Be sure to read instructions on McLube can
before using. Spray McLube on sails in a well-ventilated
area, away from the Carbo Racing Foil. Let McLube
dry completely before feeding sail into foil. McLube or
other toluene- or acetone-based lubricants must not be
sprayed on or near foil. Spraying McLube directly on
Carbo Racing Foil may damage it.
WARNING!: Do not spray foil on boat. McLube will
cause slippery decks which may result loss of footing,
falling overboard and personal injury or death.
If storing mast down, foil should be reasonably straight, foil groove down to
avoid water and ice buildup.
Before stepping mast, use soap and water to clean Carbo Racing Foil grooves.
Storing
01
97653 14879
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