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.
https://www.mysticparts.com/Assets/images/pennparts/schematics/525magt.pdf (https://www.mysticparts.com/Assets/images/pennparts/schematics/525magt.pdf)
and here is our reel.
(http://alantani.com/gallery/2/1_10_02_10_2_59_51_4.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_00_05_5.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_00_09_6.jpeg)
start by removing the left side plate screws (key #'s 32 and 110).
(http://alantani.com/gallery/2/1_10_02_10_3_06_49_2.jpeg)
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).
(http://alantani.com/gallery/2/1_10_02_10_3_06_52_3.jpeg)
remove the left side ring (key #28).
(http://alantani.com/gallery/2/1_10_02_10_3_06_55_4.jpeg)
remove the left side plate (key #27).
(http://alantani.com/gallery/2/1_10_02_10_3_15_55_0.jpeg)
here's an inside view of the left side plate, showing the magnet.
(http://alantani.com/gallery/2/1_10_02_10_3_15_58_1.jpeg)
remove the spool assembly (key #29L).
(http://alantani.com/gallery/2/1_10_02_10_3_16_00_2.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_16_03_3.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_16_06_4.jpeg)
here's a quick glance inside the frame (key #183).
(http://alantani.com/gallery/2/1_10_02_10_3_17_21_0.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_17_26_1.jpeg)
we're going to take a moment to clean up the frame a little.
(http://alantani.com/gallery/2/1_10_02_10_3_17_30_2.jpeg)
now, back to the spool. remove the spool spindle (key #71L).
(http://alantani.com/gallery/2/1_10_02_10_3_17_33_3.jpeg)
remove the clutch plate retainer (key #71C).
(http://alantani.com/gallery/2/1_10_02_10_3_17_37_4.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_19_17_0.jpeg)
remove the clutch plate (key #71B).
(http://alantani.com/gallery/2/1_10_02_10_3_19_58_1.jpeg)
remove the right spool bearing (key #55). it measures 0.185 x 0.375 x 0.125 inches.
(http://alantani.com/gallery/2/1_10_02_10_3_20_55_2.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_3_21_30_3.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_3_21_49_4.jpeg)
install the right spool bearing (key #55).
(http://alantani.com/gallery/2/1_10_02_10_3_28_50_0.jpeg)
install the clutch plate (key #71B).
(http://alantani.com/gallery/2/1_10_02_10_3_28_55_1.jpeg)
install the clutch plate retainer (key #71C). you know, that retaining ring doesn't look like it's got a very good grip.
(http://alantani.com/gallery/2/1_10_02_10_3_28_58_2.jpeg)
let's flip the clutch plate over and reinstall the retainer.
(http://alantani.com/gallery/2/1_10_02_10_3_29_00_3.jpeg)
there, that looks like the ring has a better grip.
(http://alantani.com/gallery/2/1_10_02_10_3_29_05_4.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_3_31_04_0.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_31_07_1.jpeg)
remove the left side spool bearing (key #55). this bearing also measures 0.185 x 0.375 x 0.125 inches.
(http://alantani.com/gallery/2/1_10_02_10_3_31_11_2.jpeg)
clean, lube and reinstall this bearing (key #55) in the same way.
(http://alantani.com/gallery/2/1_10_02_10_3_31_14_3.jpeg)
before you install the click ratchet (key #81), match up the grooves.
(http://alantani.com/gallery/2/1_10_02_10_3_31_18_4.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_32_54_0.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_33_04_1.jpeg)
install the spool spindle (key #71L).
(http://alantani.com/gallery/2/1_10_02_10_3_33_07_2.jpeg)
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!
(http://alantani.com/gallery/2/1_10_02_10_3_33_10_3.jpeg)
install the spool assembly (key #29L).
(http://alantani.com/gallery/2/1_10_02_10_3_33_14_4.jpeg)
take a moment to grease the screw holes.
(http://alantani.com/gallery/2/1_10_02_10_3_35_14_0.jpeg)
install the left side plate (key #27).
(http://alantani.com/gallery/2/1_10_02_10_3_35_21_1.jpeg)
install the left side ring (key #28).
(http://alantani.com/gallery/2/1_10_02_10_3_35_24_2.jpeg)
install the two long left side plate screws (key #32) and the one short left side plate screw (key #110).
(http://alantani.com/gallery/2/1_10_02_10_3_35_26_3.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_3_35_29_4.jpeg)
now for the right side plate. remove the handle lock screw (key #32A).
(http://alantani.com/gallery/2/1_10_02_10_3_41_37_0.jpeg)
remove the handle lock (key #110A).
(http://alantani.com/gallery/2/1_10_02_10_3_41_40_1.jpeg)
remove the handle nut (key #23) using a 7/16ths wrench.
(http://alantani.com/gallery/2/1_10_02_10_3_41_42_2.jpeg)
remove the handle (key #24).
(http://alantani.com/gallery/2/1_10_02_10_3_41_46_3.jpeg)
remove the tension spring washer (key #8). i usually throw these away. they tend to cause corrosion.
(http://alantani.com/gallery/2/1_10_02_10_3_41_48_4.jpeg)
remove the star drag (key #10).
(http://alantani.com/gallery/2/1_10_02_10_3_43_26_0.jpeg)
remove the tension spring washer (key #18).
(http://alantani.com/gallery/2/1_10_02_10_3_43_28_1.jpeg)
remove the two right side plate screws (key #32).
(http://alantani.com/gallery/2/1_10_02_10_3_43_31_2.jpeg)
push the eccentric lever (key #21) straight up.
(http://alantani.com/gallery/2/1_10_02_10_3_43_33_3.jpeg)
remove the right side ring (key #2).
(http://alantani.com/gallery/2/1_10_02_10_3_43_37_4.jpeg)
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).
(http://alantani.com/gallery/2/1_10_02_10_3_44_52_0.jpeg)
remove the right side plate screw (key #39S).
(http://alantani.com/gallery/2/1_10_02_10_3_44_55_1.jpeg)
remove the two lower right side plate screws (key #46).
(http://alantani.com/gallery/2/1_10_02_10_3_45_00_2.jpeg)
remove the right side plate assembly (key #1).
(http://alantani.com/gallery/2/1_10_02_10_3_45_04_3.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_45_06_4.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_49_01_0.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_3_49_04_1.jpeg)
remove the clutch shaft (key #98S).
(http://alantani.com/gallery/2/1_10_02_10_3_49_07_2.jpeg)
remove the entire drag stack as a unit (key #'s 5, 6 and 7C).
(http://alantani.com/gallery/2/1_10_02_10_3_49_10_3.jpeg)
remove the fiber washer (key #4).
(http://alantani.com/gallery/2/1_10_02_10_3_54_56_0.jpeg)
remove the ratchet spacer (key #98R).
(http://alantani.com/gallery/2/1_10_02_10_3_55_00_1.jpeg)
remove the two clutch springs (key #18B).
(http://alantani.com/gallery/2/1_10_02_10_3_55_06_2.jpeg)
remove the pinion gear (key #13) and the pinion yoke (key #12) as a unit.
(http://alantani.com/gallery/2/1_10_02_10_3_55_10_3.jpeg)
remove the eccentric jack (key #11).
(http://alantani.com/gallery/2/1_10_02_10_3_55_13_4.jpeg)
remove the two bearing retainer screws (key #63).
(http://alantani.com/gallery/2/1_10_02_10_3_58_54_0.jpeg)
remove the gear stud (key #134) and bearing (key #20A) as a unit. this bearing measures 8 x 16 x 5mm.
(http://alantani.com/gallery/2/1_10_02_10_3_59_02_2.jpeg)
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).
(http://alantani.com/gallery/2/1_10_02_10_3_59_06_3.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_3_59_08_4.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_4_02_26_0.jpeg)
remove the shields of this bearing (key #20A), pack it with grease and replace the shields.
(http://alantani.com/gallery/2/1_10_02_10_4_02_29_1.jpeg)
reinstall the packed bearing (key #20A) and the bearing screw (key #121).
(http://alantani.com/gallery/2/1_10_02_10_4_02_32_2.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_4_02_34_3.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_4_08_11_0.jpeg)
ok, we are NOW ready to put everything back together.
(http://alantani.com/gallery/2/1_10_02_10_4_08_14_1.jpeg)
install the gear stud (key #134), bearing (key #20A) and screw (key #121) as a unit.
(http://alantani.com/gallery/2/1_10_02_10_4_08_17_2.jpeg)
install the bearing retainer (key #173).
(http://alantani.com/gallery/2/1_10_02_10_4_08_19_3.jpeg)
install the bearing retainer screws (key #63).
(http://alantani.com/gallery/2/1_10_02_10_4_08_23_4.jpeg)
install the eccentric jack (key #11).
(http://alantani.com/gallery/2/1_10_02_10_4_09_44_0.jpeg)
install the pinion gear (key #13) and pinion yoke (key #12) as a unit.
(http://alantani.com/gallery/2/1_10_02_10_4_09_49_1.jpeg)
install the clutch springs (key #18B).
(http://alantani.com/gallery/2/1_10_02_10_4_09_51_2.jpeg)
install the ratchet spacer (key #98R).
(http://alantani.com/gallery/2/1_10_02_10_4_09_54_3.jpeg)
we are going to replace the fiber washer (key #4) with a penn ht-100 #6-113 drag washer.
(http://alantani.com/gallery/2/1_10_02_10_4_09_56_4.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_4_13_16_0.jpeg)
install the main gear (key #5).
(http://alantani.com/gallery/2/1_10_02_10_4_13_23_1.jpeg)
slap a thick coat of cal's grease on the three drag washers (key #6).
(http://alantani.com/gallery/2/1_10_02_10_4_13_28_2.jpeg)
install the drag washers (key #6) alternating with the metal washers (key #7C) and the clutch shaft (key #98S).
(http://alantani.com/gallery/2/1_10_02_10_4_13_32_3.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_4_13_35_4.jpeg)
put a small bead of grease in the screw holes of the frame (key #183).
(http://alantani.com/gallery/2/1_10_02_10_4_19_45_0.jpeg)
flip the eccentric lever (key #21) forward and install the right main side plate (key #1).
(http://alantani.com/gallery/2/1_10_02_10_4_19_48_1.jpeg)
install the two lower right side plate screws (key #46).
(http://alantani.com/gallery/2/1_10_02_10_4_19_51_2.jpeg)
install the small right side plate screw (key #39S).
(http://alantani.com/gallery/2/1_10_02_10_4_19_53_3.jpeg)
move the eccentric lever (key #21) to the center and install the right side ring (key #2).
(http://alantani.com/gallery/2/1_10_02_10_4_23_07_0.jpeg)
install the two right side plate screws (key #32).
(http://alantani.com/gallery/2/1_10_02_10_4_23_11_1.jpeg)
install the tension spring (key #18).
(http://alantani.com/gallery/2/1_10_02_10_4_23_14_2.jpeg)
install the star drag (key #10) and turn it down until it clears the shoulders of the gear stud (key #134).
(http://alantani.com/gallery/2/1_10_02_10_4_23_17_3.jpeg)
remember the tension spring washer (key #8)? all it does is cause corrosion, so we are going to throw it away.
(http://alantani.com/gallery/2/1_10_02_10_4_23_23_4.jpeg)
install the handle (key #24).
(http://alantani.com/gallery/2/1_10_02_10_4_31_20_0.jpeg)
install the handle nut (key #23).
(http://alantani.com/gallery/2/1_10_02_10_4_31_27_1.jpeg)
install the handle nut lock cap (key #110A).
(http://alantani.com/gallery/2/1_10_02_10_4_31_31_2.jpeg)
install the handle lock screw (key #32A).
(http://alantani.com/gallery/2/1_10_02_10_4_31_41_3.jpeg)
install the spool assembly (key #29L).
(http://alantani.com/gallery/2/1_10_02_10_4_31_51_4.jpeg)
install the left side plate (key #27) and left side ring (key #28).
(http://alantani.com/gallery/2/1_10_02_10_4_42_49_0.jpeg)
install the left side plate screws (key #'s 32 and 110).
(http://alantani.com/gallery/2/1_10_02_10_4_42_51_1.jpeg)
congratulations, you're done!
(http://alantani.com/gallery/2/1_10_02_10_4_42_54_2.jpeg)
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.
(http://alantani.com/gallery/2/1_10_02_10_4_43_02_4.jpeg)
(http://alantani.com/gallery/2/1_10_02_10_4_43_41_1.jpeg)
ok, now we're done!
"Edited as per Moderators to correct Scott's Bait & Tackle over to their new store name Mystic Reel Parts / www.mysticparts.com"
Quote from: My Phoenix;93527Alan you are the best instructor. I have the Penn 545 reel and have already worked on it by trial and error. This series would have been great for me. I am impressed that you took the time to document even the incorrect way to install some of the parts so we can tell when things just aren't right. I have a few questions so I better understand your approach to working on reels. First, you put the shield back on the gear stud bearings. Why did you do that as you usually recommend removal of the shields? What is your criteria for the decision? Second, did you intentionally not put a coating of grease on the eccentric jack and that area of the reel? Third, does not the tension spring washer help hold the star drag at a given setting, preventing it from backing off unintentionally? I added a tension spring washer to a friends Shimano reel to prevent such backing off. Do you recommend the removal of all tension spring washers? Thanks so much for sharing your expertise.
John
you're welcomed, john. spool bearings should be left open and lubed for the best spin. if freespool is not an issue, pack them with grease. if a bearing is open and greased, it should last for a long time. if a bearing is shielded and grease, it should last forever. all the pieces that were reinstalled had a light coating of grease. sorry about not making that clear. it comes from being handled with greasy fingers and then being cleaned up a little with a greasy rag. the tension spring UNDER the star helps keep the star from backing off. the tension on top of the star is often free floating and does nothing until you back it off all the way. you can leave the star buttoned down forever. as far as other tension washers goes, it sort of depends on whether they actually do any good and how much corrosion they cause down the line. thanks for asking. alan
Quote from: kingfisherman23;6902810Great post, Alan! The 525s are a great lineup. A few notes... I find that the most common places for corrosion to appear in these reels are the reel foot, under the silver star drag shroud and around the side tension knob. The clutch plate on every Penn 525 I've worked on has the same problem you detailed. I think it is a function of the assembly. It can be very irritating the first time you run into it, but the plate simply will not go back onto the spool the same way as it comes off. On the standard 525 with the sliding mag, there is a small screw on both sideplates of the reel. I don't know why it is there. Perhaps just to discourage you from working on it LOL! Finally, as you install the right side right it is imperative that you make sure the tips seat into the cuts of the sideplate. I saw one that didn't set and tightening the screws caused the ring to bend and had to be replaced. Evan
Quote from: dsurf;570249Superb detail and close-up work........I did not see any mention of the left side plate bearing.....most folks don't realize it's there. It's not identified on any schematic I've seen. Same size as right side plate bearing that's under tension knob. Primarily only comes into play when there's force on spool, i.e hauling in a fish. According to Penn it has no role when casting.....only retrieving with a load. It's under the brass cap on left side plate (in your 8th photo from the top) which houses the left end of spool spindle. Not sure why Penn left it off schematic because if you order a left side plate, it does not come with it. You have to tell them to send you a
#55A bearing (which is the right side plate bearing.) Getting this brass cap off without damaging can be a real challenge. I use a small round nose pliers with protective covering (like thin cloth).
wow, never saw it! actually, i would think that it would have no role, casting or retrieving........
dear alan,
can the anti reverse roller bearing rotated 180 degree and installed so that the i can reel using my left hand , correct me if i am wrong
it would not work. you have a right hand gear set in this reel.
(http://alantani.com/gallery/2/1_10_02_10_4_13_23_1.jpeg)
the way the gears are cut, there is downward pressure from the main gear to the pinion gear down onto the spool shaft. in a left hand configuration, the pinion gear would be lifted up and away from the spool. this would disengage the pinion gear from the spool. alan
thanks alan for the reply , would like to know the max drag pressure for the mag 525
max i do not know, but the reel should be able to easily handle 50 pound spectra and a 30-40# topshot with up to 12 #'s of drag. alan
Hello, Alan. I just had a quick question. Where can I find bearing shield replacements? After packing the gear stud bearing with grease, you said to replace the shields. Thanks!
seals and metal shields with retaining rings can be replaced. the pressed in shields have to be dug out and are mangled in the process. sorry, there are no replacements.
My 525 was knocked over on the beach the other day, sand got into the whole reel - should I replace all bearings and washers or will cleaning re-lubing work? I don't think the drag washers were initially greased so they might be ruined?
clean overthing out with fresh water, then compressed air. the gears are likely already damaged from the sand. can't help that. drags can be greased and re-installed. open up the spool bearings and clean them out, then re-lube them. non spool bearings should also be opened up, then packed with gease. it will be tedious.
Can you put the 4.25 gears into this reel? Has anyone done this conversion?
these are the only conversion kits i am aware of. a kit for the 525 is not listed.
https://www.mysticparts.com/PennParts/Kits/GearKits.aspx (https://www.mysticparts.com/PennParts/Kits/GearKits.aspx)
"Edited as per Moderators to correct Scott's Bait & Tackle over to their new store name Mystic Reel Parts / www.mysticparts.com"
Thanks Alan, I checked that out, there was a set on eBay that I lost, if I knew how hard they were to find I would have bidder more. The 6.0 gears I have in this reel just don't work for me, I had a couple big blues hooked that I thought were about to strip the gears.
my buddy Billy directed me to your website
I just serviced a 525 mag, but. did not greased the drags
because I don't have the right kind of grease
Billy will send me some to go back and finish the job.
I bought a used Saltist reel with greased drags and they felt loose,
so I tightened them just to pull the hook from a big yellow
so I guess it had the wrong grease ? because they feel light but when the
farming was done, I checked the drags and were very tight
?
with the wrong grease, the drags usually lock up. check for metal washers out of order, thrust washers along the handle drive shaft out of order, and spectra slipping on the spool. those are the first things that come to mind. please keep us in the loop. alan
Not to threadjack, but can the left side plate of the 525T (UK) fit the 525 (US)?