Harken REFLEX FURLING Unit 1 User manual

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
REFLEX™FURLING
Unit 1, 2
Installation Manual – Intended for specialized personnel or expert users
5015 04-16
Table of contents
Preassembly
Safety precautions 2
Part descriptions/terms 2 -3
Size check 3
Parts 4
Additional parts required/tools 5
Dimensions/sailmaker's Instructions 6
Cable length worksheet 7
Assembly
Threaded adapter 8
Terminating torsion cable to head swivel 9 -11
Terminating torsion cable to tack swivel 11
Determining cable length at boat 12
Cutting torsion cable and final assembly 13-14
Commissioning
Loading furling line in drive unit 15
Mounting fairleads/line to cockpit 16
Attaching sail to unit 17
Operation
Raising sail first time/halyard tension 17
Furling 18
Lowering sail/hoisting furled sail/sail changes 19
Sail changes 19
Maintenance
Cleaning parts and bearing assemblies 20
Warranty 20

Reflex furler
2
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.
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
The Harken Reflex™ furling system for asymmetric spinnakers is used for handling free-flying downwind and reaching
sails. These sails have a loose positive luff that is longer than the leech and are called asymmetric spinnakers, cruising
spinnakers, or gennakers. Use of this product for other than normal sailboat applications is not covered
by the limited warranty.
Safety Precautions
1) Head swivel
2) Torsion cable clamps
3) Heat shrink tube
4) Reflex torsion cable
5) Tack swivel terminal
6) Fixed tack terminal
7) Drive unit
8) D-shackle threaded adapter (optional)
9) Snap shackle threaded adapter
10) 2:1 soft attach threaded adapter
Part Descriptions 1
2
3
5
7
8
9
10
2
4
6
3

Reflex furler 3
Preassembly Terms - Size Check
Size Check
Check recommended boat and sail size. Note: If you also plan to use the system for code zero sails, the loads
will be higher so max boat and sail size will be smaller. If using for multihulls downsize maximums by 10%.
Unit
size Unit part no. Intended application Typical boat length Maximum sail area
m ft m2ft2
17351.10 Asymmetric spinnaker 7.5 - 11 25-36 112 1200
7361.10 code zero 6.7 - 10 22-32 60 650
27352.10 Asymmetric spinnaker 10 - 14 34 - 45 168 1800
7362.10 code zero 9 - 12 30 - 40 84 900
Terms
Set screw holes
Thimble
Lineguard
Drive sheave
Flexible cowling
T-slot
Locking spring pin
T-foot
Tack swivel terminal
Head swivel
Drive unit
Snap shackle threaded adapter
Feeder

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4
Preassembly Parts
Head swivel
Tack swivel terminal
Drive unit Snap shackle threaded adapter
Cable clamp set
Main Components Unit 1 Unit 2
Head swivel* 7351.28 7352.28
Tack swivel terminal* 7351.26 7352.26
Drive unit 7351.10BASE 7352.10BASE
Reflex torsion cable (ordered by the foot)* 7371 7372
Included in 7351.10 or 7352.10 systems
Unit 7371 cable length Unit 7371 cable length
7351.10.16M 16.15 m (53') 7352.10.20M 20.12 m (66')
7351.10.18M 18.29 m (60') 7352.10.23M 22.87 m (75')
7351.10.20M 20.12 m (66') 7352.10.25M 25 m (82')
Torsion cable clamp set* 7357 7358
Snap shackle threaded adapter 7351.20 7352.20
Optional components
Fixed tack terminal (code zero sail)* 7351.27 7352.27
Reflex torsion cable spool (914 m - 3000')* 7371.SPOOL 7372.SPOOL
D-shackle threaded adapter 7351.21 7352.21
D shackle only - high resistance (HR) 2109 (6 mm HR) 2116 (8 mm HR)
2:1/soft attachment threaded adapter 7351.22 7352.22
Reflex torsion cable
*Order these components for extra sails. Note: Each extra sail has a head swivel, torsion cable, clamp, and track terminal
Fixed tack terminal for
code zero sail
D-shackle threaded
adapter D shackle only
2:1/soft attachment threaded adapter
Optional components
Main components

Reflex furler 5
Continuous furling line - Talk to your rigging supplier about furling line construction using a structural cover over
a nonstructural core. Note: Have the rigger capture the aft block in the loop before making the loop. The furling line
loop can load into the stanchion leads and the drive unit after the line is spliced into a loop.
Determining furling line length - Refer to the chart below for line size and length. Double the loop length and add
enough length for the overlap in the end-for-end splice.
Preassembly Additional Parts Required - Tools
Tools Required
1. Long tape measure 4. Hacksaw
2. Short tape measure 5 Heat gun
3. Hex keys
13
Sail attachments - Use a shorter soft shackle for head of sail and a longer soft
shackle for the tack of sail. Consult a rigging supplier, a knot tying book or see
a link to instructions at www.harken.com/knots.
Unit Line diameter Length of loop - cruise Length of loop - race
16 mm (1/4") Measure from furler to aft cockpit block Use J dimension, plus bow sprit, minus 60 cm (2')
28 mm (5/16")
2
4
7356 fairlead kit - For cruising, lead the furling line loop back to the cockpit.
Leads fit 25 mm (1") stanchions. Includes two double fairleads, a double
fairlead with cleats, and aft block with bungee.
7355 double fairlead - Order if additional stanchion positions are required.
XXXX Aft block with bungee - Order for race boat attachment near shrouds.
7355 fairlead
7356 kit
Aft block with bungee
5

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Snap shackle D-shackle Diam Line ht. Tack swivel Hole top Thimble top Hole bottom Thimble bot. Clamp ht.
A A B C D E F H I J
UNIT 1
7351.10 Reflex furling system - Asymmetric spinnakers
55 mm 28 mm 140 mm 54 mm 94 mm 114 mm 131mm 53 mm 83 mm 50 mm
2.16" 1.12" 5.5" 2.13" 3.7" 4.5" 5.17" 2.08" 3.27" 1.97"
7361.10 Reflex furling system - Code zero sails
55 mm 28 mm 140 mm 54 mm 103 mm 120 mm 53 mm 83 mm 50 mm
2.16" 1.12" 5.5" 2.13" 4.04" 4.71" 2.08" 3.27" 1.97"
UNIT 2
7352.10 Reflex furling system - Asymmetric spinnakers
61 mm 38 mm 167 mm 64 111 mm 134 mm 152 mm 76 mm 93 mm 60 mm
2.41" 1.49" 6.59" 2.52" 4.35" 5.28" 5.97" 2.98" 3.67" 2.36"
7362.10 Reflex furling system - Code zero sails
61 mm 38 mm 167 mm 64 121 mm 138 mm 76 mm 93 mm 60 mm
2.41" 1.49" 6.59" 2.52" 4.76" 5.47" 2.98" 3.67" 2.36"
*
A A A
C D E E
H I
J
Dimensions - Sailmakers's Instructions
Luff length - asymmetric spinnaker
Note offset H at the top and offset D at the bottom. When using system
for asymmetric spinnakers, D represents the attachment point to the tack
swivel terminal.
Luff length - code zero
Note offset H at the top and offset E at the bottom representing the
attachment points for the sail cloth.
Code zero luff cable
The Reflex torsion cable is designed for use with asymmetric sails and
transmits torque at lower halyard loads. When using the Reflex torsion
cable with a code zero sail, make sure there is an additional rope to handle
tension. Alternatively, use a tension receiving rope that is torsionally
resistant and splice it to the thimble in the head swivel and the fixed tack
terminal. This alternate method will require more tension to furl, making
furling more difficult.
IMPORTANT! When using a 2:1 tack line, remember that it is pulling
against the halyard. Downsize the diameter of the 2:1 tack line so
that it does not overpower the stretch of the halyard.
F
F
Fixed tack terminal
for code zero sails
Threaded adapters
Tack swivel terminal for
asymmetric spinnakers

Reflex furler 7
Preassembly Cable Length
REFLEX CABLE LENGTH WORKSHEET
1. Use long tape measure
secured to shackle and hoisted
to masthead. Measure FH length
from full-hoist shackle to extended
bowsprit fitting with mast in
forward setting
2. Determine A dimension depending on unit size and fill in the chart below.
Note: If using a 2:1 soft attach, measure or estimate the lowest A dimension.
A - Bottom of unit to bearing point of threaded adapter
Threaded adapter Unit 1 part no. and A distance Unit 2 part no. and A distance
2:1 soft attachment 7351.20 7352.20
D-shackle 7351.20 28 mm 1.12" 7352.21 38 mm 1.49"
Snap shackle 7351.20 55 mm 2.16" 7352.22 61 mm 2.41"
Cable length worksheet
Description Unit 1 Unit 2
mm in mm in
FH Full hoist shackle to bow forward attachment
A Threaded adapter length to bottom of unit Subtract
L Length (FH minus A) Length (L) is also the cable length CL
L
A
A
A
FH
Use rig dimensions and worksheet below
to determine cable length. Determine final
measurements when building the terminals.
IMPORTANT! Use mast forward position. Do not
make cable too long or it cannot tension.
3. Use the worksheet below to determine the cable length (CL). Note the cable length (CL) is equal to the length (L).
Make final length adjustments during assembly. The lengths below accommodate cable stretch when the halyard is
tensioned.

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8
Assembly Threaded Adapter
Back the adapter out no more than one (1)
rotation until the set screw holes line up
with the recesses at the top of the threaded
adapter. Sight into one of the set screw
holes to confirm alignment.
IMPORTANT! Make sure the adapter is
either parallel or perpendicular to the
feeder opening.
The parallel or perpendicular position
will depend on the fitting on the bow
sprit or extended bow fitting.
Thread the adapter completely into the
drive unit until it stops.
Install set screws using threadlocking
solution such as blue Loctite® adhesive.
2:1 soft attach threaded adapter installs
the same way as above.
Tip: Load the
loop or 2:1 adjuster in the adapter before
installing.
Tip: The D-shackle adapter and snap
shackle adapters use the same threaded
bases so you can switch the shackles to
change types.
Loctite is a registered trademark of Henkel AG & Company KGaA.

Reflex furler 9
Assembly Clamping Torsion Cable to Head Swivel Terminal
IMPORTANT! - Wait to cut the torsion cable to length until you have clamped the cable to the head swivel. Plan on
a length check with drive unit as you build the tack terminal.
2. Slide the heat-shrink tubing onto the
cable. Assemble the clamp halves near the
cable end using four (4) longer screws
threaded into the corner holes. Turn several
turns as shown and leave enough space to
load the cable end.
3. Insert the end of the cable through
thimble at the head swivel and position it at
the desired location on the cable. Slide the
clamp assembly over the end of the cable
as shown.
Tip: Secure the head swivel in a
vise when building the terminal to hold it
in place.
1. Locate the clamp halves and the long
fasteners (M5 X 25 mm) as shown. Cut the
supplied heat-shrink tubing in half.
4. Push the clamp assembly toward the
thimble. Squeeze the torsion cable at the
thimble. Position clamp about 10 mm (3/8")
from the thimble as shown. Make the tail of
the cable about 90 mm (3.5") beyond the
clamp.

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Assembly Clamping Torsion Cable to Head Swivel Terminal
IMPORTANT! - Wait to cut the torsion cable to length until you have clamped the cable to the head swivel. Plan on
a length check with drive unit as you build the tack terminal.
6. Continue to tighten the four (4) corner
fasteners until the gap between the clamp
halves is around 5 mm (3/16"). Now tighten
the two center fasteners until snug.
7. Remove each of the long corner fasteners
and replace with a short fastener using blue
Loctite.
5. Gradually tighten each of the four (4)
corner fasteners, alternating to maintain a
relatively even gap between clamp halves.
When the gap is about 8 mm (5/16"), locate
two (2) of the short fasteners supplied (M5
X 16 mm). Apply blue Loctite and thread
the fasteners into the two remaining screw
locations. It is not necessary to tighten these
at this time.
8. Gradually tighten all fasteners, alternating
to maintain a relatively even gap between the
clamp halves. Assembly is complete when
all fasteners achieve a maximum torque of
5.6 Nm 50 in-lb (5.6 Nm). The gap between
the clamp halves should be even and nearly
closed.

Reflex furler 11
Assembly Clamping Torsion Cable to Head Swivel Terminal - Tack Terminal
9. Slip shrink tubing over end and use heat
gun to cover end and main cable.
IMPORTANT! Be careful not to damage
cover of Reflex cable.
10. If assembling away from the boat,
lay cable out straight. Install tack swivel
terminal on drive unit. Install the threaded
adapter.
IMPORTANT! Slide the heat-shrink tubing
onto the cable before slipping the cable
into the thimble. Slip the cable into the
thimble and check to make sure the unit
is shorter than the (FH) full-hoist length
by the amount shown in the chart. Clamp
cable and use hacksaw to cut the cable
leaving a tail of:
Unit 1 - 90 mm (3.5")
Unit 2 - 100 mm (4")
Tip: Leave a longer tail if you are not
sure about measuerments. See following
pages on determining length at boat.
Stretch length
at load
Estimated stretch length at load
Full hoist (FH) length Unit 1 Unit 2
14 to 16 m (45 to 53') 200 mm 8" - -
16 to 18 m (53 to 59') 240 mm 9 1/2" 300 mm 12"
18 to 20 m (59 to 66')
280 mm 11" 350 mm 14"
20 to 23 m (66 to 75') 320 mm 13" 400 mm 16"
23 to 25 m (75 to 82') - - 450 mm 18"
Heat-shrink
tubing
Full hoist (FH)
11. Follow the procedure used to build the
head swivel terminal.
Note: Wait to shrink the heat-shrink tubing
until the sail is hoisted and sailed in case
length adjustments are necessary.
Wait to heat
shrink tubing

Reflex furler
12
Physical length determination at the boat - Use instead of measuring and referring to charts.
Moor the boat so you can reach the end of the sprit from the dock. Have the mast in forward setting for running;
use a halyard to pull the mast forward.
2. Finding cut length: Attach the lower unit
assembly to the tack line or fixed bail and
pull the tack line all the way down. Slip the
bottom of the cable through the thimble in
the tack terminal. Pull the cable as tight as
you can by hand, and wrap a piece of
electrical tape where the cable
enters the thimble as a mark.
1. Dry-fit setup at boat: Hoist the head
swivel with cable installed to the top of the
mast. Bottom end of cable will be open, no
lower unit.
Install the tack swivel terminal on the drive
unit by pulling the locking spring pin and
slipping the T-foot of the terminal into the
T-slot in the drive unit.
Tape here
Assembly Determining Cable Length at Boat

Reflex furler 13
Amount to pull through thimble - Estimated stretch length at load
Full hoist (FH) length Unit 1 Unit 2
14 to 16 m (45 to 53') 200 mm 8" - -
16 to 18 m (53 to 59') 240 mm 9 1/2" 300 mm 12"
18 to 20 m (59 to 66') 280 mm 11" 350 mm 14"
20 to 23 m (66 to 75') 320 mm 13" 400 mm 16"
23 to 25 m (75 to 82') - - 450 mm 18"
4. Finding stretch length: Refer to the
chart at right and use tape to mark the
cable the distance shown. The mark will
be located at the point where the cable
enters the thimble. It represents the
amount of stretch when the torsion rope
is tensioned when hoisted.
IMPORTANT! Slide the shrink wrap onto
the cable before slipping cable into
thimble.
5. Setting the length - Slip the cable into
the thimble and pull it through until the
mark from step 4 is at the point where
the cable enters the thimble.
3. Cutting the cable: Lower the cable to
the dock. Clamp the cable to the dock and
cut the cable using a hacksaw.
Note: Cutting the cable at the mark may
seem too short; however, when the hal-
yard tensions, the cable will stretch from
200 to 400 mm (8 -16"), depending on
the unit size and the cable length.
Tip: If you prefer, cut the cable so it is
a few inches longer and use a Dremel-
type small circular saw to cut it after
assembly and applying halyard loads.
Stretch length at load
New position at thimble top
Stretch length
at load
Shrink tubing
Full hoist (w)
Original cut from step 3
Assembly Cutting Cable - Adjjusting Length and Assembly at Boat

Reflex furler
14
8. Checking the length: Attach the drive
unit to the bow fitting or pole. Hoist the
cable without sail to check the length. Use
the halyard winch to tension the halyard
enough to straighten the cable.
Tip: Unlike fibrous torsion cables, the
Reflex torsion cable transmits torque
at lower halyard loads.
IMPORTANT!
Over-tensioning the halyard can make
furling more difficult and can damage
components.
Adjust the tack line if necessary.
6. Building the tack terminal: Follow the
procedure used to build the head swivel
terminal.
Tip: Wait to shrink the heat shrink tub-
ing until the sail is hoisted and sailed in
case length adjustments are necessary.
Do not use heat-
shrink tube until
length is set.
Assembly Building Terminal and Length Chck at Boat

Reflex furler 15
Commissioning Loading line
Work the line into the space between the
drive sheave and the flexible cowling.
Make sure the torsion cable is not attached
to the drive unit. Load the looped furling
line into the line guard.
Rotate the drive sheave as you press the
line into position around the drive sheave.
Load the final part by pulling the line from
outside the drive unit.

Reflex furler
16
Mounting farleads to stanchions: Furling line can be led down
either side of boat. The leads are designed for running furling
line outboard of the stanchions. Note: Do not run the line on the
inboard side of stanchion.
Plan the lead system referring to the diagram below. The lead with
cleats should be easily accessible. The aft block with bungee keeps
some tension on the furling line.
Remove four screws on stanchion leads.
Note: Clamp leads to stanchion so the black plastic clamp side is
inboard and the metal line guide is outboard.
Tip: Start all four (4) screws before tightening.
Inboard
Outboard
Load the furling line loop into the fairleads by rotating the line to
line up with the openings. Push the line into place.
7355 fairlead
7359 fairlead with
cleats
Aft block with
bungee
Aft block is used at the end of the system.
For racing: Mount the aft block with bungee
near the shrouds. By using a clip at the end of
the bungee cord you can easily clip it to port
side or starboard. For distance racing, furling
can always be on the weather side.
Commissioning Mounting Fairleads - Line to Cockpit

Reflex furler 17
Pre-hoist checklist
There are several assembly steps described in detail in the installation manual.
• Lower drive unit attached to bow with line guard facing aft
• Looped furling line installed on drive unit and led aft
• Head swivel and tack swivel clamped to torsion cable and length checked
• Swivel tack terminal attached to lower drive unit
• Soft-attach shackle available for attaching head of sail to head shackle
• Soft-attach lashing or shackle available and sized for attaching tack to swivel tack terminal
Preparation for first sail hoist: Sail is in bag, unfurled.
Tip: Pick light breeze conditions. Have no jib or have jib furled. Subsequent hoists will be much easier because
sail will be furled.
Tip: Temporarily secure the furled jibsheets downward toward the deck to help keep the Reflex furling system,
spinnaker sheets, and halyard outside of the jib sheets.
Attach the head of the sail to the eye in the head swivel
using a soft shackle or lashing.
Secure tack of sail using soft-attach long shackle.
Make length adjustable for adjustment when sail is
finally fitted.
Load the Reflex swivel tack terminal into the T-slot on the lower drive unit. Attach the unit to the bow sprit or a
fixed point on the bow ahead of the stay. Attach halyard to head swivel and check halyard and sheet leads. Hoist
and trim spinnaker.
Halyard Tension: Tension the halyard to pull slack out of the Reflex torsion cable. Adjust the tack line if neces-
sary. Use the winch to pull the halyard until the rolled sail is straight. IMPORTANT! Over-tensioning the halyard
can make furling more difficult as you load components. Unlike fibrous torsion cables, the Reflex torsion
cable transmits torque at lower halyard loads. Too much tension can damage components.
Operation Raising Sail First Time

Reflex furler
18
Furling
Prepare both spinnaker sheets so they are ready to
run. Pull the continuous furling line and the lower
drive unit rotates the Reflex torsion cable which
immediately rotates the head swivel, furling the sail
around the torsion cable beginning at the top.
Tip: When furling, control the amount the
sail flogs. From a broad reach, ease the
sheets to reduce sail power. Start furling
and then ease more.
Operation
The sail tack is on a swivel and does not begin
furling until most of the sail is furled.
Continue furling by easing the sheet part way and
furling so flogging is minimized and there is some
drag on the sheets. Furl until the clew pennant or
sheets are securely wrapped around the furled sail.
The furling action is top-to-bottom; furling starts at the sail head and moves downward.
Furling

Reflex furler 19
Operation Lowering Sail - Hoisting Furled Sail - Sail Changes
Lowering: Lower the rolled sail and remove the entire unit from
the retracted sprit, or use the T-slot and leave the lower drive unit
with furling line and sheets on the bow. Coil the furled sail in a
large bag. Tip: A large rectangular bag (3:1 ratio) stows nicely. If
removing the lower drive unit, gather the furling line and sheets
into the bag.
Hoisting furled sail:
After the initial hoist and furl, the Reflex system will be ready for hoisting while furled. These items were covered
previously in the first sail-hoist section.
Checklist:
• Head of sail securely attached to head swivel
• Tack secured to tack swivel terminal
• Tack swivel terminal loaded into T-slot in lower drive unit
• Unit secured to bowsprit or bow fitting
• Furling line led aft below jib sheets to aft lead block
• Spinnaker sheets attached, and led around forestay and aft to spinnaker blocks outside and above all
other sheets
• Halyard attached
Hoisting steps:
• Pull tack out to pole if adjustable
• Pull bowsprit out
• Hoist furled sail from the weather side to avoid having to go under the foot of the jib. The head swivel
stays ahead of the rig. Work the furled sail outboard and forward while hoisting furled sail.
Unfurling sail:
Make sure sheets are led correctly and leeward sheet is ready to trim. Make sure that the furling line is clear to
run and people are clear of the line.
As you are unfurling, head up a little so wind begins to unfurl the sail. As it is filling, bear off to reduce the
wind in the sail. Let the sail unfurl and spin the furling line.
WARNING! Stand clear of the drive sheave and the furling line when sail is unfurling. Trying to
grab the line and slow it can result in injury. Keep fingers clear of the spinning drive sheave.

Reflex furler
20
Sail Changes: Changing furled sails is easy. Components are available for each sail.
Asymmetric spinnakers - Order these additional parts.
• Head swivel
• Tack swivel terminal
• Reflex torsion cable
• Torsion cable clamp set
Code zero sails - Order these additional parts.
• Head swivel
• Fixed tack terminal
• Reflex torsion cable
• Torsion cable clamp set
The sail may have an existing torsion rope in the luff. Talk to your sailmaker about installing a Harken Reflex tor-
sion cable. Requires a separate Dyneema® type tension-bearing luff rope.
Changing Sails: With the new sail furled and ready to go, changing sails is quick and easy. Simply pull the
spring pin, slide out one (1) assembly and slide the new sail assembly into the lower drive unit. You can even
switch from a free-flying sail to a code zero sail. Note the fixed tack terminal. Switch sheets and hoist as normal.
Dyneema is a registered trademark of DSM IP Assets B.V.L.L.C