"A" series shimano calcutta 400 rebuild

[twicebitten]

Excellent step-by-step write up and pictures. I'm not as mechanical as I would like to be, but this post made taking apart and reassembling easy. Good thing, too as I found one of the #1613 washers is cracked (assuming it is not supposed to be) and found rust on the anti-reverse roller clutch bearing (key #1207).

I am going to do this one over again once I get replacement pieces and switch over to carbontex drag washers (if they are available). This will also allow me to figure out why the clutch bar seems a little stuck when pressing down with my thumb or re-engaging with a twist of the reel handle.

Thanks again!

[PescadorPete]

I've had issues with replacing the washer that is under the main gear. If it is not thick enough the reel won't go out of gear when you press down on the bar. I leave the hard washer under the main gear and replace the others with the recommended Penn 965 washers. Still way more drag than you need and no binding when disengaging the spool.

[iclypso]

Just got a 400s off of ebay. I took it apart and found that is missing one of the gray brake collars on the LHS of the spool. Anyone know if this is a big problem and, if so, where I can find these?

I also found that the reel is missing the spacing washer just underneath the star (directly above the bellvilles, it's P/N BNT1289). Anyone willing to measure their spacer for me so I can find a replacement?

Update: I found the brake collar online at Mike's Reel Repair for < $1. Still interested in whether or not the missing piece is critical to the reel's performance and the dims of the spacer.

[PescadorPete]

Hint: Just give Shimano a call. If the order is small, they might not charge for the parts or the postage.

[dan1]

Alan, can the A series be upgraded to B series with the anti-reverse dog?

[MattA]

Hi Alan - you've previously given me advice about overhauling my Calcutta 400. I recently installed some Carbontex drag washers (which are great) and in the process, managed to confuse the orientation of the 5 metal washers that sit under the star drag. I attempted to figure out exactly which Calcutta 400 I have, so I could download the appropriate schematic, however didn't know where to start the identification process. Any hints?

Also, based on the schematic for the CT400, I tried to ascertain which way the 5 metal washers should be assembled. I assembled them as follows - is this correct. This is from my notes to myself:

1. The 5 metal washers that sit underneath the drag star : two thick (1455), two thin (1613), one odd (1289). They go like this : from next to the reel spool, working towards the handle :
(i) two thick, placed so that their curved surfaces create a gap between the two washers.
(ii) two thin, placed so that their curved surfaces create a gap between the two washers.
(iii) the remaining 'odd' washer - placed so that its curve replicates the curve on the very first washer.

Any help on this would be much appreciated!

Regards

Matthew

[icscommand]

Great photos and instructions. I have 4 of these and a Corsair also. The only issues I have with them, is occasionally the "dog pawl" will fail to engage and you have to "bitch slap" it. Shimano said they don't seem to have a problem with the reels. Broke it down and clean them, but could see nothing unusual. Sent the worst one to Shimano for repair.
Anybody else have same issue?
Thanks again.

[alantani]

matt, your instincts are good! you've got it right!

dean, the leaf springs on the dog get spread out too much and won't grab properly. you just have to squeeze them together again.