penn 525 mag T rebuild - 2/14/2010

penn 525 mag T rebuild - 2/14/2010

penn makes a nice series of graphite reels.  they're light,  they've got plenty of drag range, and they're very easy to service.  here's a link to the schematic.

http://www.scottsbt.com/catalog/store/images/pennparts/schematics/525magt.pdf

and here is our reel.







start by removing the left side plate screws (key #'s 32 and 110).



note that you have two long screws at the 3 and 9 o'clock positions (key #32) and one short screw at the 6 o'clock position (key #110).



remove the left side ring (key #28).



remove the left side plate (key #27).



here's an inside view of the left side plate, showing the magnet.



remove the spool assembly (key #29L).







here's a quick glance inside the frame (key #183).





we're going to take a moment to clean up the frame a little.



now, back to the spool.  remove the spool spindle (key #71L).



remove the clutch plate retainer (key #71C).





remove the clutch plate (key #71B).



remove the right spool bearing (key #55).  it measures 0.185 x 0.375 x 0.125 inches.



remove the shields from this bearing, clean it with carb cleaner and compressed air, and lube it with xtreme reel +.  for a full discussion of bearing maintenance, go to http://alantani.com/index.php?topic=13.0. 



i've seen some spools with alot of corrosion on the ends.  clean up the spool an old toothbrush and leave a light coat of grease on it to prevent corrosion.



install the right spool bearing (key #55).



install the clutch plate (key #71B).



install the clutch plate retainer (key #71C).  you know, that retaining ring doesn't look like it's got a very good grip.



let's flip the clutch plate over and reinstall the retainer. 



there, that looks like the ring has a better grip.



use a flat screwdriver to CAREFULLY lift up the click ratchet (key #81).  please do not break this.  if you have two screwdrivers, place them at 180 dregrees, turn the blades clockwise and lift both sides simultaneously. i just can't do this and take a picture at the same time. 





remove the left side spool bearing (key #55).  this bearing also measures 0.185 x 0.375 x 0.125 inches.



clean, lube and reinstall this bearing (key #55) in the same way. 



before you install the click ratchet (key #81), match up the grooves.







install the spool spindle (key #71L).



now give it a spin.  using the stock abec 5 bearing, shields remove, clean and lubed with xtreme reel +, this bare spool spun for 2 minutes and 25 seconds.  and that was without holding a beer in my left hand!



install the spool assembly (key #29L).



take a moment to grease the screw holes.



install the left side plate (key #27). 



install the left side ring (key #28).



install the two long left side plate screws (key #32) and the one short left side plate screw (key #110).



now spin the spool.  with the magnet backed all the way off, the spool spins for only 8 seconds.  with the magnet cranked all the way in, freespool drops to 3 seconds.



now for the right side plate.  remove the handle lock screw (key #32A).



remove the handle lock (key #110A).



remove the handle nut (key #23) using a 7/16ths wrench.



remove the handle (key #24).



remove the tension spring washer (key #8).  i usually throw these away.  they tend to cause corrosion.



remove the star drag (key #10).



remove the tension spring washer (key #18).



remove the two right side plate screws (key #32).



push the eccentric lever (key #21) straight up.



remove the right side ring (key #2).



this is someone's idea of a joke.  there is a small right side plate screw (key #39S) hidden underneath the right side ring (key #2).



remove the right side plate screw (key #39S).



remove the two lower right side plate screws (key #46).



remove the right side plate assembly (key #1).







take a moment to check out the gear stack.  we've got a stainless steel pinion gear and a brass alloy main gear.  it also has a stack of three drag washers that functions as a traditional stack of five.



remove the clutch shaft (key #98S).



remove the entire drag stack as a unit (key #'s 5, 6 and 7C).



remove the fiber washer (key #4).



remove the ratchet spacer (key #98R).



remove the two clutch springs (key #18B).



remove the pinion gear (key #13) and the pinion yoke (key #12) as a unit.



remove the eccentric jack (key #11).



remove the two bearing retainer screws (key #63).



remove the gear stud (key #134) and bearing (key #20A) as a unit.  this bearing measures 8 x 16 x 5mm.



insert the top of the gear stud (key #134) into the hanlde (key #24) so that you have something to hold on to and remove the bearing screw (key #121).







remove the shields of this bearing (key #20A), pack it with grease and replace the shields. 



reinstall the packed bearing (key #20A) and the bearing screw (key #121).



well, now we have a problem.  we need to pack the pinion bearing (no key #) with grease. to get to it, we will have to back track and remove the spool. 



with the spool removed, the pinion bearing (no key #) taps out easily.  it measures 8 x 12 x 2.5mm.  the bearing should be cleaned, packed with grease and reinstalled.



ok, we are NOW ready to put everything back together.



install the gear stud (key #134), bearing (key #20A) and screw (key #121) as a unit.



install the bearing retainer (key #173).



install the bearing retainer screws (key #63).



install the eccentric jack (key #11).



install the pinion gear (key #13) and pinion yoke (key #12) as a unit.



install the clutch springs (key #18B).



install the ratchet spacer (key #98R).



we are going to replace the fiber washer (key #4) with a penn ht-100 #6-113 drag washer. 



slap a thick coat of cal's grease on the washer before installing it.  don't worry about the excess grease.  it will simply squeeze out the sides. 



install the main gear (key #5).



slap a thick coat of cal's grease on the three drag washers (key #6).



install the drag washers (key #6) alternating with the metal washers (key #7C) and the clutch shaft (key #98S).



i almost forgot about the right side plate bearing (key #55A).  this bearing measures 0.125 x 0.375 x 0.156 inches.  this bearing can be difficult to open and pack, so we're going to just lube it with corrosion x and keep out fingers crossed that it does not corrode.  lube the anti-reverse roller bearing with corrosion x as well.



put a small bead of grease in the screw holes of the frame (key #183).



flip the eccentric lever (key #21) forward and install the right main side plate (key #1).



install the two lower right side plate screws (key #46).



install the small right side plate screw (key #39S).



move the eccentric lever (key #21) to the center and install the right side ring (key #2).



install the two right side plate screws (key #32).



install the tension spring (key #18).



install the star drag (key #10) and turn it down until it clears the shoulders of the gear stud (key #134).



remember the tension spring washer (key #8)?  all it does is cause corrosion, so we are going to throw it away.



install the handle (key #24).



install the handle nut (key #23).



install the handle nut lock cap (key #110A).



install the handle lock screw (key #32A).



install the spool assembly (key #29L).



install the left side plate (key #27) and left side ring (key #28).



install the left side plate screws (key #'s 32 and 110).



congratulations, you're done!



well, almost.  no rebuild would be complete without the signature handle upgrade.  here's the same reel with a chromed arm and a 4/0 kolekar grip.





ok, now we're done!

Thank you Alan for another great picture tutorial!

Thanks Alan for your great attention to detail.