Reel Repair by Alan Tani

Conventional and Bait Casting Reel Rebuild Tutorials and Questions => Daiwa Tutorials and Questions => Topic started by: Lunker Larry on October 11, 2016, 02:55:13 PM

Title: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on October 11, 2016, 02:55:13 PM
I've had 2 Lexas in this week, a HS-P and PWR-P. These are fresh water reels. The issue with both reels seem to be the anti reverse pawl. I haven't diagnosed what is causing the issue but I'm guessing it isn't aligning properly or works its way off its pin. In the picture, the PWR-P is on the left and the HS-P is on the right. The pawl was completely off its pin and the copper guides broken right off on the left taking a chunk out of the yoke and breaking up the oscillating gear. The pawl was also off on the HS-P and it broke a chunk off the yoke.
Initially the muskie community here thought these were a great alternative to the TRANX and to get away from the issues with the Revo Toro NACL and Winch but they are not holding up. Users are tired of repair and are giving up on them.
Anyone else seen this or having other issues with the reel?
Title: Re: Daiwa Lexa 400 Issues?
Post by: Bryan Young on October 11, 2016, 04:39:08 PM
Quote from: Lunker Larry on October 11, 2016, 02:55:13 PM
I've had 2 Lexas in this week, a HS-P and PWR-P. These are fresh water reels. The issue with both reels seem to be the anti reverse pawl. I haven't diagnosed what is causing the issue but I'm guessing it isn't aligning properly or works its way off its pin. In the picture, the PWR-P is on the left and the HS-P is on the right. The pawl was completely off its pin and the copper guides broken right off on the left taking a chunk out of the yoke and breaking up the oscillating gear. The pin was also off on the HS-P and it broke a chunk off the yoke.
Initially the muskie community here thought these were a great alternative to the TRANX and to get away from the issues with the Revo Toro NACL and Winch but they are not holding up. Users are tired of repair and are giving up on them.
Anyone else seen this or having other issues with the reel?

Oh, that's looks really bad.
Title: Re: Daiwa Lexa 400 Issues?
Post by: johndtuttle on October 11, 2016, 05:34:52 PM
Quote from: Lunker Larry on October 11, 2016, 02:55:13 PM
I've had 2 Lexas in this week, a HS-P and PWR-P. These are fresh water reels. The issue with both reels seem to be the anti reverse pawl. I haven't diagnosed what is causing the issue but I'm guessing it isn't aligning properly or works its way off its pin. In the picture, the PWR-P is on the left and the HS-P is on the right. The pawl was completely off its pin and the copper guides broken right off on the left taking a chunk out of the yoke and breaking up the oscillating gear. The pin was also off on the HS-P and it broke a chunk off the yoke.
Initially the muskie community here thought these were a great alternative to the TRANX and to get away from the issues with the Revo Toro NACL and Winch but they are not holding up. Users are tired of repair and are giving up on them.
Anyone else seen this or having other issues with the reel?

There is no doubt that the Lexa is not as heavily built as a Tranx, its an issue of the large price and heft penalty. Is it the reel for one's fishing?

Looks like the dog jumped off the pin or the pin itself came out of it's slot. Once they get loose then bad things are going to happen.

I think only Daiwa can tell us if this is common. They have sold a ton of these reels.
Title: Re: Daiwa Lexa 400 Issues?
Post by: MarkT on October 11, 2016, 05:53:45 PM
Wow, that looks pretty bad. I wonder how that happened? I've caught several Wahoo and dozens of Yellowtail with my Lexa 400hs-p with no issues. I have to think they put more strain on the reel than a Muskie. I was throwing Raider jigs for Wahoo and JRI 4 surface iron for Yellowail, both of which are about 4 oz/125 gm.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Gfish on October 11, 2016, 06:14:14 PM
I've had mine for 2 yrs. now, casting lures inshore for various reef and surf dwellers, no issues yet. However, I been waitin' to see what kinda durability issues might come up, given the price point. Got a 400 PWR-P. Thanks for the detailed post LL. Keepin my fingers crossed, I really like mine so far...
Gfish
Title: Re: Daiwa Lexa 400 Issues?
Post by: johndtuttle on October 11, 2016, 08:12:49 PM
Quote from: MarkT on October 11, 2016, 05:53:45 PM
Wow, that looks pretty bad. I wonder how that happened? I've caught several Wahoo and dozens of Yellowtail with my Lexa 400hs-p with no issues. I have to think they put more strain on the reel than a Muskie. I was throwing Raider jigs for Wahoo and JRI 4 surface iron for Yellowail, both of which are about 4 oz/125 gm.

The only thing I can imagine might be a snag...yanking and yanking then the frame flexing enough for the pin to be able to get out of it's hole.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on October 12, 2016, 11:59:22 PM
Spoke with Daiwa today. The woman I spoke to said the only issue she was aware of was "rough gears". I sent a email with the photo and she was going to forward to the service manager. I'll keep you updated.
Title: Re: Daiwa Lexa 400 Issues?
Post by: handi2 on October 13, 2016, 12:12:56 AM
Thanks Larry,

I use the 400 and 300 and use them in heavy saltwater fishing. No issues so far. Only fish scales!!
Title: Re: Daiwa Lexa 400 Issues?
Post by: PERRO on October 13, 2016, 09:14:37 PM
I've been using a " daiwa Lexa "  for about two years, tossing Large Swimbaits ( Freshwater / Monthly use).

I  took it apart ( brand New ) to make sure it was properly greased. The Drag system was bone dry & I used Cals Grease, along with cleaning re-greasing all the internal parts thoroughly.

NO Problems/issues with it !! However, it has now started to feel a bit rough & I'll be doing another cleaning & greasing soon.

(http://i80.photobucket.com/albums/j161/A-PAPI/IMG_2092_zpsahcm9cna.jpg)

I was a bit concerned, it wouldn't handle long term use with tossing heavier " 10+ once Heavy Swimbaits ".. ?
(http://i80.photobucket.com/albums/j161/A-PAPI/IMG_2091_zpsizxehokk.jpg)

I just picked up a " Truth SM Surf Reel ", for a Heavy Plug/Swimbait Casting Reel.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on October 20, 2016, 05:32:03 PM
Spoke with Daiwa today. This has been forwarded to the R&D manager by the Service manager. The R&D manager is on the road at the moment but they promised they will get back to me on this.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on November 18, 2016, 01:22:58 AM
Got this today from Daiwa.

Good Morning Larry,

            After speaking to the Service Manager & R & D guys, they both told me that they haven't seen this problem much, maybe like once or twice. They did want you to know that all of our reels do come with a 1 year warranty for manufacture defect from the date of purchase. So if you run across this problem just have the reels be sent in to an authorized service center or to us directly so we can take a look at the reel. 





Daiwa Corporation



Yetssenia Tornez

CSR Customer Service

11137 Warland Dr.

Cypress, CA 90630
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on November 18, 2016, 01:31:37 AM
I'm still waiting for the oscillating gear. Anyone know of a shop in the US I might be able to get one faster than what Daiwa can do?
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on November 24, 2016, 04:49:06 PM
7 weeks and still no drive gear (2402260) from Daiwa.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on September 05, 2019, 03:21:06 PM
Just an update on the issue. I have done at least a half dozen of these reels with the same problem and and spoke with the repair depot where I get my parts and he said he sees it all the time and that you muskie guys are hard on these reels. I just want to give a heads up to owners to keep an eye on this and if anything starts feeling strange in the reel to stop using it. This reel felt perfectly fine. I opened it up for a guy who was going to sell it to someone.
To me the problem is the AR pawl or ratchet gear wobbles or something causing misalignment and the ratchet gear to jam into the AR pawl.


Title: Re: Daiwa Lexa 400 Issues?
Post by: Cor on September 05, 2019, 06:56:35 PM
ouch...i've never seen anything like this.
Title: Re: Daiwa Lexa 400 Issues?
Post by: SoCalAngler on September 05, 2019, 08:21:00 PM
Dang, In order for the anti-reverse pawl to come into play doesn't that mean the anti-reverse bearing or what Daiwa calls the "anti-reverse clutch" is not working? The pawl seems to be there as a backup to the ARB. I would think in order for the pawl to get that much damage it would have to suffer multiple failures over time of the ARB or one failure on a very large hard charging fish.

I'd take out the pawl and do some testing of the ARB.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Gfish on September 05, 2019, 08:27:55 PM
Hmmm, 6 times or more for you, Larry and Yetssenia Tornez( cool name) was only talkin 'bout "once or twice", 3 years ago. Sounds like they didn't bother to check their records back then. Who knows, in the real world where many don't contact the company about this kinda stuff, once or twice could actually = 10 or 20 times, or 100 or 200 times, etc.

I recall the ARB as not being too heavy duty. My prime suspect parts would be the AR pawl and that kinda rinky-dink, stamped-out AR ratchet, after an ARB failure.
Title: Re: Daiwa Lexa 400 Issues?
Post by: sabaman1 on September 05, 2019, 09:08:56 PM
Larry, thats alot of bad luck! You might want to move on and stop using the Daiwas, time to possibly think seriously about getting a Tranx soon.
Title: Re: Daiwa Lexa 400 Issues?
Post by: xjchad on September 05, 2019, 11:15:04 PM
I'm thinking it's not the ARB, or AR pawl.
Looks to me like something is causing the thin copper "fingers" that hold the AR pawl to the ratchet plate to fail.  Once they fail, the pawl can come off it's pin and the chunks of copper get bounced around the gear case causing damage.
Is there a mechanical stop that limits the travel of the pawl AWAY from the ratchet plate?
Could the pawl travel too far off the ratchet on a hard cast or bump that the copper fingers come off the ratchet plate???
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on September 06, 2019, 02:36:06 AM
Quote from: sabaman1 on September 05, 2019, 09:08:56 PM
Larry, thats alot of bad luck! You might want to move on and stop using the Daiwas, time to possibly think seriously about getting a Tranx soon.

These are all reels in for servicing. I was thinking once of getting one but started seeing this. Too bad as they're smooth as silk and a great drag.
Title: Re: Daiwa Lexa 400 Issues?
Post by: CooldadE on September 06, 2019, 03:55:28 AM
Crap! I just picked one up... haven't even put line on it yet. Wondering if I should dump it or just fish it and take my chances...if I do I better bring a back up reel . Not my preferred scenario...

Cool
Title: Re: Daiwa Lexa 400 Issues?
Post by: bhale1 on September 06, 2019, 05:27:57 AM
I have to agree with SoCal here... seems to me the only way this happens is if the ARB is not working properly. Only other thing is lack of proper maintenance and the back up dog gets stuck out of alignment due to old grease or salt deposits an cannot function properly! Just speculating ;D
Brett
Title: Re: Daiwa Lexa 400 Issues?
Post by: xjchad on September 06, 2019, 05:40:59 AM
Larry,
Do you have one that's getting scrapped you could send me to look at?
I've got some ideas.
Chad
Title: Re: Daiwa Lexa 400 Issues?
Post by: Gfish on September 06, 2019, 08:00:06 AM
Quote from: bhale1 on September 06, 2019, 05:27:57 AM
I have to agree with SoCal here... seems to me the only way this happens is if the ARB is not working properly. Only other thing is lack of proper maintenance and the back up dog gets stuck out of alignment due to old grease or salt deposits an cannot function properly! Just speculating ;D
Brett

L.L. said in his first post that they were freshwater reels. ARB failure sounds right. Do ARB's tend to fail if used only in fw?
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on September 06, 2019, 12:06:57 PM
The AR pawl is a cheap fix so the guys will fix it and use it as a back up or dump it.
Ref the ARB. I haven't seen a bad one in years and that was from years of no lubrication in older ABUs and the nylon race would wear out.

I keep thinking the whole stack may get too loose when casting and is misaligned when the reel is engaged.
Also the most damage is always to the top guide. Maybe the little tack weld that holds the guide fins on lets go. The picture shows the bottom side of the pawl and the tack weld
Title: Re: Daiwa Lexa 400 Issues?
Post by: Gfish on September 06, 2019, 02:35:57 PM
I recall a fix-tutorial for the S. Torium's AR pawl, that involved removing the dog ears and fabricating a spring. It worked on mine, but shortly after I did it, I donated the reel. AR components in the Torium also looked kinda cheap, so maybe it didn't last and perhaps it wouldn't work well on the Lexa. I don't have mine with me or I'd look into it
Title: Re: Daiwa Lexa 400 Issues?
Post by: day0ne on September 06, 2019, 06:49:41 PM
One question. Are we talking about the original 400 or the 400HD.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Cor on September 06, 2019, 06:54:27 PM
Quote from: Gfish on September 06, 2019, 02:35:57 PM
I recall a fix-tutorial for the S. Torium's AR pawl, that involved removing the dog ears and fabricating a spring. It worked on mine, but shortly after I did it, I donated the reel. AR components in the Torium also looked kinda cheap, so maybe it didn't last and perhaps it wouldn't work well on the Lexa. I don't have mine with me or I'd look into it
Yes I did mine and fixed problem.   Trinidad DC pawl and spring fits as is.
TGT1304   Anti-Reverse Pawl Spring
TGT1303   Anti-Reverse Pawl
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on September 06, 2019, 07:28:57 PM
Quote from: day0ne on September 06, 2019, 06:49:41 PM
One question. Are we talking about the original 400 or the 400HD.

This is a LEXA 400 HS-P. I've seen this on the LEXA XSP, PWR-P and HSP also.
The AR pawl is the same in all the current Lexa H series - HL-PWRL-P, H-PWR-P, HS-P, H-P, PWR-P AND H-P, HSL AND HSL-P.
Title: Re: Daiwa Lexa 400 Issues?
Post by: xjchad on September 06, 2019, 07:31:06 PM
Larry,
Can you post a pic of the driveshaft, ratchet plate, and pawl in position in the gearcase?
Title: Re: Daiwa Lexa 400 Issues?
Post by: Donnyboat on September 06, 2019, 08:33:43 PM
Bottom line is, know good sending a boy out to do a mans job, to heavier gear & to much drag on a small reel, I serviced, one about two weeks ago, the top of the pinion, had disintegrated, but the arb was still working, cheers Don.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on September 06, 2019, 08:44:43 PM
Quote from: xjchad on September 06, 2019, 07:31:06 PM
Larry,
Can you post a pic of the driveshaft, ratchet plate, and pawl in position in the gearcase?

Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on September 06, 2019, 08:49:20 PM
One more if it helps
Title: Re: Daiwa Lexa 400 Issues?
Post by: xjchad on September 06, 2019, 09:02:50 PM
It sure looks like the driveshaft rotated backwards and the pawl slipped under the ratchet plate, the ratchet caught the copper finger on top and shoved the pawl under it and into the pinion yoke.

This would indicate a failure of the ARB (I was wrong  :D ) and also a bad contact point between the contact surface of the pawl and ratchet tooth.  Maybe the punch tooling for the pawl, ratchet, or both was dull and the end surfaces have an angle instead of being perpendicular.  

Does that make sense? Maybe a quick rendering will help?
(https://www.fishy-pix.com/wp-content/uploads/2019/09/Assem1.jpg)

Does that model have a heavy power handle with no counterbalance?
Maybe the ARB could be slipping on a cast?
A 10 oz. swimbait getting stopped short from a back lash would put a lot of load on that ARB.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Gfish on September 06, 2019, 10:30:46 PM
Sounds and looks logical Chad. I remember the ratchet on my non-HD, P-PWR 400, looked thin and yeah, ever so slightly rounded on the edges. Don't recall anything special about the dog. Perhaps they didn't put any effort(or $) into designing something of quality, comparable to the rest of the reel, 'cause it's supposed to be a back-up AR system.
Title: Re: Daiwa Lexa 400 Issues?
Post by: boon on September 09, 2019, 05:38:34 AM
These are one of those reels where, just because it says it can make 25lbs of drag, doesn't mean it should be fished out there. I had a 400 and it was spooled with 20lb braid, and was well suited to that kind of fishing. Honestly I wouldn't fish one beyond about 40lb, but each to their own.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on October 25, 2019, 01:36:56 PM
Here's another issue I've seen a number of times. There is a little brass (?) clip on the yoke that gets torn off and jammed up in the reel.

Title: Re: Daiwa Lexa 400 Issues?
Post by: jurelometer on October 25, 2019, 07:02:32 PM
Chad may be on the right track,  but the anti reverse system  (AR bearing and  pawl/dog)  will not be connected to the spool when  the reel is in freespool (even  during a backlash).  My guess is that the damage is related to casting, as Chad suspected, but only if the free spool is engaged/disengaged under load.  This could tear up the yoke, and create enough force to overpower the anti-reverse bearing.

  First of all,  muskie are not going to be tearing up reels.  They just don't pull that hard or run that far.  Not disparaging a fine gamefish,  i am just trying to narrow down the issues.  But muskie guys will fish huge plugs, and that can be tough on a levelwind reel. 

Now throw that huge plug at some structure along a shoreline, where muskies like to  hang out.   Oops, cast going to far,  plug is  pulling with  much force to stop by thumbing, so turn the handle to stop the cast.  Or the reel is accidentally going into gear when casting.  Or maybe the caster has a habit of lobbing the plug and turning the handle so that the plug is moving when it hits the water. Or maybe disengaging the free spool when trolling a giant plug, etc., etc.

  The yoke is  at  greatest risk of damage when going in and out of gear.  Once the gears are engaged, the axial thrust from radial load on the helical gears will drive the pinion toward the spool, so the yolk should be entirely out of the picture when in the reel is in gear.  That is why Diawa is (almost) getting away with a nylon yoke, and just needs a small chunk of bearing metal at the rub point.

Regarding the dogs:  on most star drags, the drag holds the pawl (ratchet) in place, so if the problem is the pawl moving, it means that the whole shaft is moving, which should also damage the gears  (which is not happening?).  On the other hand,  dogs that float on a post can flop around and possibly end up under the pawl.  And with silent dogs, it is probably tempting for the designer to assume that the dog ears will hold the dog flat to the pawl. But dog ears are not very sturdy.

From the photos on your reel and John Tuttle's tutorial, it looks to me like the dog ears might be a bit too small for the size of the square gap between the pawl teeth.  If an edge gets caught, the ear is going to get torn up.  By looking at the marks on the dog and ratchet, you can see if the dog itself is getting driven under the ratchet, or  if it is just the ear getting damaged.   If the dog ear gets bent a bit, maybe that is enough for it to start catching during the wind and getting further shredded.  BTW, square pawl teeth allow the same part to be used for right and left hand reels,  but the square gap is more likely to catch a dog ear.

One other note: the photos seem to show that the top of the pawl and dogs are not at the same height, but this may be an optical illusion.

If Chad and my theories are on the right track, then the damage can be avoided by being more diligent about NOT going in and out of free spool under load, which is always hard on a star drag, but is going to be very hard on a lightweight reel working big plugs.

-J

Title: Re: Daiwa Lexa 400 Issues?
Post by: Three se7ens on October 25, 2019, 11:25:29 PM
Just looking at whats in this thread, I think the square notches, and the short length of the ears on the silent dog are the real problem hear.  The square notches must look nice from a cost standpoint(interchangeable with left and right hand models), but I think it really degrades the quality of the action.  And the ears are WAY too short, they should always contact a solid part of the gear, even with the dog fully disengaged.

I suspect the problem comes from the ears getting caught in the notches, and tearing up the rest of the system when they get bent.
Title: Re: Daiwa Lexa 400 Issues?
Post by: CooldadE on October 25, 2019, 11:43:36 PM
Has anybody fished one of these reels and not had it break ? I have a 400... the one with the lower gears that I haven't even put line on it yet. Should I cut my losses and look for a comparable but better low profile reel ?

Cool
Title: Re: Daiwa Lexa 400 Issues?
Post by: Swami805 on October 25, 2019, 11:56:15 PM
I got one cheap on sale a couple weeks ago,$114 all in seemed reasonable. Pretty popular reel out here. Hope it works out ok, I'll be using it with a 30lb top shot, thinking it will hold up if not abused.
Title: Re: Daiwa Lexa 400 Issues?
Post by: MarkT on October 26, 2019, 01:13:08 AM
I've caught YT, YFT, Wahoo, Skipjack, the 3B's without any issues. Todd (Hardy Boy) used it at Cedros this year, caught a bunch of YT throwing surface iron, and loved it.  It went on my 10 day at the beginning of Oct and is going on my next 10 day in a week and a half. It's full of 50# spectra with a 40# leader. A few years ago on a SoA trip at San Martin, I threw a Tady 45 on the slide then the Captain decided he wasn't ready to stop after all, I hooked up and was told tough, we aren't stopping. I cranked in the 25# YT anyway. The deckhands were impressed!

I have the HD 400hs-p. I had a 300hs-p that never had any issues. I sold it and now have a TranX 300, it's going on the 10 day again this year. I caught YFT on it last year.
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on October 30, 2019, 02:45:28 PM
Yes, muskie guys are very hard on reels. I'm in total agreement with your posts that the issue is the large baits, the ratchet gear catching the ears on the pawl and that it is happening on long bomb casts.
I put a shim under the AR pawl on one of these reels and want to see if it makes any difference.

Interesting problems that I have not seen on any other reel.

Great discussion and insightful comments.

LL
Title: Re: Daiwa Lexa 400 Issues?
Post by: xjchad on October 30, 2019, 03:07:34 PM
Keep us posted Larry!
It would be cool to see a solution to this!
Title: Re: Daiwa Lexa 400 Issues?
Post by: Hamachi on January 11, 2020, 12:07:25 AM
So, with all this concern about the Lexa reel, I thought I'd open mine even though I've hadn't had any problems. I should've taken a picture, but nothing was out of the ordinary except black shrapnel distributed through out the drivetrain. The only place it could have come from is the yoke. Looking at it you can hardly tell anything is wrong, but I'm hoping someone will come up with a solution, Metal yoke maybe?
Title: Re: Daiwa Lexa 400 Issues?
Post by: Lunker Larry on January 11, 2020, 03:11:23 AM
I've seen that also. Little curls shaved off the yoke and other pieces. Some were chewed up pretty good