SERVICE MANUAL

Routine flushing, the fixes for halyard wrap and hard furling, how to identify your Harken furler family and unit size, and the accessories and lead blocks for each unit.

DocumentHarken Jib Reefing & Furling Systems Quick Service
FormatPDF · 2 pages · 0.4 MB
LanguageEnglish
Harken Jib Reefing & Furling Systems — Quick Service

Service at Regular Intervals

  • Flush the unit with soap and fresh water. Occasionally lower the sail and flush the halyard swivel with soap and fresh water.
  • At least twice a year clean more thoroughly: remove the line (first note the direction of the spool) and flush the bearings with soap and fresh water.
  • Halyard wrapping: correct the halyard angle with a wire pendant or halyard restrainer so the halyard is at an 8- to 10-degree angle from the foil, or use a halyard deflector.
  • Line jumps above the guard on MKIII or MKIV and jams: lead the line through one of the two enclosed windows in the guard.

Hard to Furl or Unfurl

  • Too little headstay tension: increase it at the turnbuckle.
  • Too much halyard tension: ease the halyard. Tensioning the backstay tightens the halyard: set the backstay, then tension the halyard.
  • Line scrapes on the line guard: too much line on the spool, or the lead block angle spools line onto the bottom. Lead at 90° (perpendicular to the headstay), then untie and adjust the sheets to reduce line if needed.
  • Line wound loosely or with overrides: make the last block in the lead system a ratchet block.
  • Too much friction in the leads: use ball bearing blocks. Furling line running backwards through the ratchet block: re-rig the block in the correct direction.
  • Stopper knot catching: MKI – dead-end with an overhand knot outside the drum; MKII, MKIII, MKIV – check it runs through the correct hole, or reduce knot size.
  • Foils scraping at top or bottom: foil too high or too low; make sure it has not dropped into the torque tube and is riding on the turnbuckle.
  • Tensioning the halyard makes it hard to furl: missing top bushing, or swivel installed upside down.

Sail Will Not Furl / Unfurl Completely

  • Too much or too little line on the drum: untie the sheets, turn the furled unit to reduce or add line, retie.
  • Line spools on the bottom of the drum and will not unfurl completely: adjust the forward lead block so the line leaves the middle of the spool at 90° to the headstay.

Family Identification

Family Line guard Spool Torque tube Screws near torque tube base Unit number / date
MKI Stainless cup, one opening Gray-anodised aluminium Straight cylinder Yes Size and date stamped on top of spool
MKII Stainless curved plate secured to gray aluminium, single line opening Gray plastic Tapered Yes No size marked (see size chart); date on hub of halyard swivel and lower unit (remove split drum)
MKIII Black aluminium, 4 openings, 2 for line Black plastic Tapered Yes No size marked (see size chart); date on hub of halyard swivel and lower unit (remove split drum)
00AL Black aluminium, 4 openings, 2 for line Black plastic Tapered top No No size marked (see size chart); date on halyard swivel and lower unit (remove drum)
MKIV Black aluminium, 4 openings, 2 for line Black plastic Tapered top No Size on label; no date marked
Cruising* Black aluminium, 4 openings, 2 for line Black plastic Straight cylinder No Size on label; no date marked
ESP* Stainless steel, 5 openings, 1 for line Black plastic None Hub extension connects to foils with set screws Measure drum Ø

*Cruising and ESP foils have a single sail groove; all other families have two. Some parts on older furlers may not be available. Pre-1987 MKI units have different locking collars for swage, Norseman/STA-LOK and rod.

Size identification (MKI, MKII, MKIII, ESP) – measure drum Ø across the top of the drum, clevis pin Ø and torque tube length

Unit size Drum Ø in (mm) Clevis pin Ø in (mm) Torque tube length in (mm)
00AL 5 3/4 (146) 1/4, 5/16, 3/8, 7/16 (6, 8, 9.5, 11.1) 9 1/2 (241)
0 5 13/16 (147) 5/16, 3/8, 7/16 (8, 9.5, 11.1) 5 7/8 (150)
1 7 7/16 (188) 1/2 (12.7) 7 7/16 (189)
1.5 7 7/16 (188) 5/8 (15.9) 13 (330)
2 9 1/2 (241) 5/8 (15.9) 10 5/16 (262)
2.5 9 1/2 (241) 3/4 (19.1) 17 1/4 (438)
3 12 (305) 3/4, 7/8 (19.1, 22.2) 13 (330)
3.25 12 (305) 7/8, 1 (22.2, 25.4) 15 (381)
ESP 0 6 1/2 (166) 5/16, 3/8 (8, 9.5) —
ESP 1 8 (200) 7/16, 1/2 (11, 12.7) —
ESP 2 9 7/8 (250) 5/8, 3/4 (15.9, 19.1) —
ESP 3 11 3/4 (298) 7/8, 1 (22.2, 25.4) —

Accessories and Lead Blocks

Accessories by Unit

Furling unit Halyard restrainer Snap shackle Halyard deflector
00AL 944 884 —
0 944 884 7301
1 944 884 7302
2 945 885 7303
3 945 — 7304
3.25 945 — —
Part no. Item
944 Halyard restrainer View part →
945 Halyard restrainer View part →
884 Snap shackle View part →
885 Snap shackle View part →
7301 Halyard deflector View part →
7302 Halyard deflector View part →
7303 Halyard deflector View part →
7304 Halyard deflector View part →

See the unit's own manual for replacement component part numbers.

Furling Lead Block Kits

  • Harken recommends Carbo lead blocks on every system for safe furling from the cockpit. The 7404 kit is a complete system for most boats and fits 25 mm (1") stanchions.
  • 7402 ratchet: maintains tension when spooling for smooth furling. 7403 outboard assembly: keeps the furling line outboard of the stanchion. 7401 40 mm block: inboard lead on the bow pulpit.
Part no. Description Sheave Ø in (mm) Max line Ø in (mm) MWL lb (kg)
7401 40 mm Carbo lead block assembly 1 9/16 (40) 3/8 (10) 485 (220) View block →
7402 57 mm Carbo ratchet lead block assembly 2 1/4 (57) 3/8 (10) 500 (227) View block →
7403 29 mm Outboard lead block assembly 1 1/8 (29) 3/8 (10) — View block →
7404 Lead block kit: 3 × 7403, 1 × 7401, 1 × 7402, 1 cleat (max line 10 mm, 3/8") — 3/8 (10) — View block →
7405 40 mm Carbo double lead block assembly 1 9/16 (40) 3/8 (10) 485 (220) View block →

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

Products in this Manual