Reel Repair by Alan Tani

Conventional and Bait Casting Reel Rebuild Tutorials and Questions => Shimano Tutorials and Questions => Topic started by: redsetta on July 12, 2011, 12:33:39 PM



Title: Shimano Calcutta 400 - carbontex upgrade
Post by: redsetta on July 12, 2011, 12:33:39 PM
G'day lads, here's a Carbontex upgrade (courtesy of Dawn at Smooth Drag) for the Shimano 400.
I just found Alan's tutorial for the 400, but seeing as I've already taken the photos etc, I figured I'd post it anyway.
I'll be sure to do something new next time!  ;D ;D
Righto, off we go...
The 400 is a cracker little reel, despite not having an anti-reverse dog.
This one was thrown out by a customer who'd fished it for a few years, lost most of the internals and eventually given up on it.
I replaced what was missing and restored the rest, and have caught some great fish on it since - including all the snapper in a previous post.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_51_197871396.jpeg)

First up, loosen the two side plate bolts - I generally keep them firmly finger tight, perhaps with just a little tweak to finish 'em off.
Pull the spool and and loosen off the handle nut cover..

(http://alantani.com/gallery/19/3590_04_08_17_5_52_51_197881483.jpeg)

Loosen the handle nut and check for the friction washer, which will usually be stuck to the bottom of the handle.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_52_197891348.jpeg)

Remove the star drag and check for the star drag spacer, which (once again) will usually be stuck to the bottom of the star.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_45_197662020.jpeg)

Remove the drag spring washers (bellevilles) - there are a number of configurations, but generally they'll be two thick (), beneath two thin ().
Remove the two screws and lift off the side plate - the anti-reverse bearing can now be pushed out of the side plate, along with the roller clutch inner tube.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_45_19765503.jpeg)

The main gear may not slide easily off the drive shaft, so remove the top drag washers.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_45_197672480.jpeg)

You should eventually be able to slide the main gear off...

(http://alantani.com/gallery/19/3590_04_08_17_5_52_46_19768730.jpeg)

Slide off the the last drag washer and the anti-reverse ratchet.
This is what it all looks like once removed...

(http://alantani.com/gallery/19/3590_04_08_17_5_52_46_197691475.jpeg)

Here are the new Carbontex washers and the old Dartanium versions.
Apply Cal's to the new fiber washers and reassemble as per the following pics...

(http://alantani.com/gallery/19/3590_04_08_17_5_52_46_197701035.jpeg)

The main gear goes down next, followed by the washer with the largest ID.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_46_197711444.jpeg)

Steel drag washer (keyed, no ears) next, followed by greased fiber (the remaining two are identical).

(http://alantani.com/gallery/19/3590_04_08_17_5_52_47_197721081.jpeg)

Eared washer next, followed by the last greased fiber washer.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_47_197731620.jpeg)

The last keyed steel washer goes down next, followed by the roller clutch inner tube.
Apply a little Cal's grease to the tube internal (a good idea of Alan's)...

(http://alantani.com/gallery/19/3590_04_08_17_5_52_47_197742238.jpeg)

Slide the tube down the drive shaft and position the tube keys in the keyed washer.
Reinsert the anti-reverse bearing into the side plate.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_48_197752032.jpeg)

Position the side plate on the set plate and replace the screws.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_48_19776165.jpeg)

Replace the spool and carefully align the spline with the pinion gear.
You'll need to slide the 'Quickfire clutch' (ie thumb cast control) upwards to align with the clutch plate.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_48_19777163.jpeg)

Nearly there now... Tighten the two side plate bolts and replace the two thick bellevilles.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_48_197781109.jpeg)

Replace the two thin bellevilles so the final configuration is ()() and be sure to apply a light coating of grease to each one as you go.
I use a slightly larger star drag spacer on my 400.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_49_197791268.jpeg)

Replace the star drag and apply a little grease to the contact patch of the friction washer.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_49_197801940.jpeg)

A little grease on the handle, where it touches the friction washer...

(http://alantani.com/gallery/19/3590_04_08_17_5_52_50_19781235.jpeg)

...reattach the handle and handle nut plate...

(http://alantani.com/gallery/19/3590_04_08_17_5_52_50_197821899.jpeg)

And just like that, you're done!

(http://alantani.com/gallery/19/3590_04_08_17_5_52_50_197831887.jpeg)

Hope that's of some value.
All the best, Justin


Title: Re: Shimano 400 - carbontex upgrade
Post by: Bryan Young on July 12, 2011, 01:27:54 PM
Nice work Justin.  How do you get those 2 pictures to sit side by side each other?


Title: Re: Shimano 400 - carbontex upgrade
Post by: alantani on July 12, 2011, 03:23:38 PM
yeah, that's what i was wondering.  also, do you know if there is a way to incorporate an ambassaduer style dog into this reel, like the later models do?  i wanted to check that out but never got around to it.  alan


Title: Re: Shimano 400 - carbontex upgrade
Post by: redsetta on July 12, 2011, 10:45:13 PM
G'day Alan/Bryan,
Right click on the photo file and scroll to 'Open With'.
Scroll down to 'Paint' and left click.
If the image is too large in 'Paint', ie you can't see the whole thing in one window, click 'Image', 'Resize' and try 50%.
Keep resizing till it's about four inches high.
Look to the right-hand side of the photo and you'll see little dots at each corner and one in the middle.
Click the middle dot and drag it out more than twice the width of the image.
Go back to the image folder and 'Open With' 'Paint' on the next image.
Hold down 'Ctrl' and click 'A' to 'Select All'.
Hold down 'Ctrl' and click 'C' to 'Copy'.
Close the second 'Paint' window and go back to the first.
Hold down 'Ctrl' and click 'V' to 'Paste' the image into this window.
It'll overlay the first one, but simply click-and-hold on the image and drag it to the right side of the first.
Line it up nicely and then click back on the white space to the right of the images.
You'll see the dot again.
Drag it back to the edge of the second photo.
Save as a new filename and you're done...
It sounds complicated, but it's quick and easy once you've done it a few times.
Hope that helps.

PS I considered adding an Ambassaduer-style dog, but I'd have to replace the current square-tooth anti-reverse ratchet with a regular bevill-edged version.
There's a redundant screw hole on the set plate for a dog set-up, but I'm not sure if the new ratchet will disengage the clutch pawl effectively.
I'll have to give it a crack now, though!


Title: Re: Shimano 400 - carbontex upgrade
Post by: Bryan Young on July 12, 2011, 11:53:08 PM
Oh that's how you do it.  Thanks Justin.


Title: Re: Shimano 400 - carbontex upgrade
Post by: redsetta on July 15, 2011, 08:33:41 PM
G'day lads,
Just finished the dog upgrade for the 400A - which was easy as pie.
The 400B dog (part BNT3361 Anti-Reverse Pawl) was about $2 and I used a stainless (316 marine grade) screw I had lying around.

(http://alantani.com/gallery/19/3590_04_08_17_5_52_50_197841280.jpeg)

There's a redundant screw hole where the dog goes and the plastic set plate can be tapped with the screw - being very careful to align it properly (and be gentle with the plastic.)

(http://alantani.com/gallery/19/3590_04_08_17_5_52_51_197851756.jpeg)

In this instance, the screw head was a little large and interfered with the main gear very slightly.
I changed out the screw, shimmed the dog/pawl up a fraction with two tiny copper washers, and 'job done'...

(http://alantani.com/gallery/19/3590_04_08_17_5_52_51_19786651.jpeg)

All the best, Justin


Title: Re: Shimano 400 - carbontex upgrade
Post by: plastic tiki on July 16, 2011, 02:31:16 AM
Now that is fricken mint!! ;D

nice work Justin, mmmmm.... i've got one that could use that treatment coming in the next week or two.


Title: Re: Shimano 400 - carbontex upgrade
Post by: Bryan Young on July 16, 2011, 05:04:29 AM
Ooh, nice...gotta love dogs pairs.


Title: Re: Shimano 400 - carbontex upgrade
Post by: joeleo2000 on July 25, 2011, 11:13:49 AM
Justin, that's an awesome upgrade!
I am working on a friends 400 right now and would like to do this mod. Can you tell me what the dimension of the screw and washers you used? 

Best Regards,
Richard


Title: Re: Shimano 400 - carbontex upgrade
Post by: redsetta on July 26, 2011, 04:00:44 PM
G'day Richard,
I'll pull it apart tonight a measure it all up.
I'm in NZ, so the timing's a bit off for you guys stateside...


Title: Re: Shimano 400 - carbontex upgrade
Post by: joeleo2000 on July 26, 2011, 08:36:07 PM
Justin how is the mod working for you? The reel I'm working on was reversing while my friend was on a fish. i cleaned the anti-reverse bearing and it looks to be in good condition. This is the first time I have seen the anti-reverse bearing not hold. I am hoping the anit-reverse pawl mod will stop it from happening again.


Title: Re: Shimano 400 - carbontex upgrade
Post by: redsetta on July 26, 2011, 09:09:57 PM
It's working well.
I've 'bench-tested' it exhaustively with a dud anti-reverse bearing and it all worked as expected.
I also fished it last weekend without issue.
The true test will come if I hook into a unexpectedly large fish and the bearing fails...
I'll get those measurements for you tonight.
All the best, Justin


Title: Re: Shimano 400 - carbontex upgrade
Post by: redsetta on July 27, 2011, 02:01:35 AM
The dog is shimed up 0.5mm.
The screw is 7.5mm long (from the base of the head to the tip) and 3mm thick.
Hope that helps.


Title: Re: Shimano 400 - carbontex upgrade
Post by: joeleo2000 on July 27, 2011, 12:45:21 PM
Justin thanks for taking the time to get the dimensions.
Going on a parts search Friday!


Title: Re: Shimano 400 - carbontex upgrade
Post by: Board4life on August 08, 2011, 01:23:13 AM
Is it common for the Calcutta 400b to be a little stiff after carbontex upgrade? Stiff meaning it is slightly harder to turn the handle. Everything seems to be working fin, just a noticeable increase of resistance when cranking.


Title: Re: Shimano 400 - carbontex upgrade
Post by: alantani on August 08, 2011, 08:56:18 AM
first thought is that the drag stack is too high and it's rubbing against the sideplate.  any possibility that one of the original drag washers was not removed?


Title: Re: Shimano 400 - carbontex upgrade
Post by: Board4life on August 08, 2011, 09:33:47 AM
No... All old drag were removed and replaced. The dog ears are making contact and it appears to be perfect. I did two conversions and they both have the same outcome. I am about to put the old ones back in and see if that fixes it. Making sure it isn't something else that I overlooked.

And when I tighten down the drag, nothing changes. Still feels the same. Not sure that is helpful.


Title: Re: Shimano 400 - carbontex upgrade
Post by: alantani on August 08, 2011, 09:59:01 AM
if the topmost metal drag washer is rubbing against either the side plate or the anti-reverse roller bearing, it will usually get worse when you back off the star.  when the star is rubbing against the side plate, it will get worse when you crank down on the star.  if there is no difference, then the resistance is somewhere else in the drive train. 


Title: Re: Shimano 400 - carbontex upgrade
Post by: Board4life on August 08, 2011, 10:09:28 AM
can you tell if the topmost metal drag washer is rubbing against either the side plate or the anti-reverse roller bearing?

Winner... You are good. So I pressed everything down as far as it will go and it is still rubbing. Do I just have to replace one of the carbontex with a thinner one? Or did I get the wrong size kit?


Title: Re: Shimano 400 - carbontex upgrade
Post by: redsetta on September 18, 2011, 05:43:46 PM
G'day all,
I'm looking for a replacement Calcutta 400 frame (#BNT-3367), if anyone has an old one (in reasonable condition) laying around...
The one I'm replacing is badly corroded.
It's just over $150 for a new one (here in NZ), so any improvement on that would probably be worthwhile (depending on postage).
PM me if you can assist...
Cheers in advance, Justin


Title: Re: Shimano 400 - carbontex upgrade
Post by: george.s on September 18, 2011, 07:07:38 PM
G'day all,
I'm looking for a replacement Calcutta 400 frame (#BNT-3367), if anyone has an old one (in reasonable condition) laying around...
The one I'm replacing is badly corroded.
It's just over $150 for a new one (here in NZ), so any improvement on that would probably be worthwhile (depending on postage).
PM me if you can assist...
Cheers in advance, Justin
I just got a price here in Australia they are $100 I don't know how much it would cost to send it to NZ.


Title: Re: Shimano 400 - carbontex upgrade
Post by: redsetta on September 18, 2011, 07:32:18 PM
Thanks George, much appreciated.
I'll do the sums and let ya know...
All the best, Justin


Title: Re: Shimano 400 - carbontex upgrade
Post by: Board4life on September 19, 2011, 10:51:22 AM
Just an update... The drag washers were too thick. However, they were replaced with the correct size... and rather fast I might add... and the reel works perfectly again.

Side note... Does anyone happen to have an extra Side plate bolt (#1698) and Washer (#3290) for the Calcutta 400B they aren't using? If so, how much you want for it?


Title: Re: Shimano 400 - carbontex upgrade
Post by: alantani on September 19, 2011, 02:11:01 PM
call shimano at 877-577-0600.  they often send out small orders like that for free.  alan


Title: Re: Shimano 400 - carbontex upgrade
Post by: Board4life on September 19, 2011, 10:24:55 PM
Thanks Alan.


Title: Re: Shimano 400 - carbontex upgrade
Post by: henryjpeterson on February 26, 2012, 12:40:57 PM
Fantastic thread. My ols Calcutta is like new again. Thank you all for contributing. Really helpful to a noob like me.


Title: Re: Shimano 400 - carbontex upgrade
Post by: alantani on February 27, 2012, 01:03:48 PM
glad it worked!


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: henryjpeterson on April 30, 2012, 10:23:06 AM
Hey gang,

Replaced my drag washers over the winter with the help of this thread. Finally took my old Calcutta 400 out to fish yesterday. Was difficult to cast. The free spool didn't seem as free as it had been in the past. Some of the guys I was fishing with were wondering about the braking system on it, if there were magnets under the left side plate I could adjust. I had no idea if it had any or not, because I didn't take off the left side plate. Only the right side plate with the real handle and drags.

Anyway, if you have any suggestions on how to rectify my not-so-free spool that would be great.  I would much appreciate any tips you could offer.

Thank you all in advance!




Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: alantani on May 04, 2012, 03:57:26 AM
no magnets on the calcutta, but there are plenty of things that would slow it down.  for the maximum amount of spin, i would recommend cleaning parts with carb or brake cleaner, them dip them in tsi 301.  we are looking at all the spool bearings, the pinion gear and the levelwind assembly.  it's going to be a big job pulling out the levelwind. 


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: JasonF on June 10, 2012, 12:36:43 PM
Using this thread in combination with Alan's CT400 thread on seŮortuna, I had my first experience at complete disassembly and drag swap to cf washers.  I have to say that it was a bunch of fun!  Now I am ordering upgrade drags for all of my reels just to have the excuse to take them apart.  Cheers! J


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: redsetta on June 10, 2012, 01:30:30 PM
Welcome Jason - good to hear it all went well.
Quote
I have to say that it was a bunch of fun!
This is how it starts! ;) ;D
All the best, Justin
PS Henry - did you get your free spool sorted?


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: JasonF on June 10, 2012, 04:51:59 PM
Thanks!  Now that I have done two CT400's the only question that I have is is the courser side of the carbon drag washer supposed to face out? I hope it is because that is how I put them! J


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: alantani on June 10, 2012, 10:02:01 PM
either way is fine!


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: Nuvole on June 11, 2012, 07:56:55 AM
Steal this thread a bit here  ;D

Will the dog fit into the conquest 50,50s,300f & sumi ika special?


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: alantani on June 11, 2012, 08:40:50 AM
not sure.  you'd have to get the parts and see.  i have some shimano parts.  if you can get a part number, i can check to see if i have it.  better yet, call shimano at 877-577-0600 with a part number.  then will often send out single parts like this for free.  alan


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: Nuvole on June 12, 2012, 07:58:01 AM
not sure.  you'd have to get the parts and see.  i have some shimano parts.  if you can get a part number, i can check to see if i have it.  better yet, call shimano at 877-577-0600 with a part number.  then will often send out single parts like this for free.  alan

The conquest only run on one way bearings which is something I don't feel good. I'm looking into modification/upgrade hence its impossible for parts number ...>_<...


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: redsetta on June 12, 2012, 02:05:34 PM
G'day Nuvole,
I don't believe there's room on the set plate of the 50 series to anchor an AR dog, but - as far as I'm aware - the 300 already has a silent dog.
There are so many variants, however, that it's hard to be 100%.
If not, I reckon it's doable. ;)
Cheers, Justin


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: Lindblom on September 18, 2015, 12:30:12 PM
Hey my name is Linus im a 20 year old boy how loves to fish, but something is wrong whit my calcutta 400b atleast i think so, when i crank the handle its sometimes gets a little bit stuck.
But when i tighten the drag i dosent happen so often, any ideas i did open the reel and did a service on the drag  washers, are they suppose to be dry or drag fat on them. Plz help Linus.


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: handi2 on September 18, 2015, 03:45:23 PM
Hey my name is Linus im a 20 year old boy how loves to fish, but something is wrong whit my calcutta 400b atleast i think so, when i crank the handle its sometimes gets a little bit stuck.
But when i tighten the drag i dosent happen so often, any ideas i did open the reel and did a service on the drag  washers, are they suppose to be dry or drag fat on them. Plz help Linus.

Hello Linus,

I'll try to help a bit. What is happening is the top metal drag washer is rubbing the inside plate of the reel. It's too high. That's why when you tighten the drag it starts to go away. When you tighten the drag star is pushes the metal drag washer down away from where it is rubbing.

I would go thru it again using the tutorial's and I'm sure you will get it right.

If you have a proper grease for the drag washers then yes they should be greased. Not too much.


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: patlao on October 25, 2018, 01:47:50 PM
G'day lads, here's a Carbontex upgrade (courtesy of Dawn at Smooth Drag) for the Shimano 400.
I just found Alan's tutorial for the 400,

Hello,

Is this the best/recommended drag upgrade? When searching I came across Alan saying to upgrade it to the Penn ht-100, cut the drags, and to bend the ears on the metal washer, but I don't know if that predates this carbon upgrade.

Thanks,
Plao


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: Darin Crofton on October 25, 2018, 01:54:06 PM
what about a 400B, is it much different?


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: redsetta on October 25, 2018, 03:22:45 PM
Hi and welcome patlao,
Both are CF, so there's nothing substantive between them (in my view).

Hey Darin,
There are a few minor differences in the bearings, handle and gear ratio (4.7:1 for the 'A' and 5:1 for the 'B' from memory)...

Hope that helps.
Cheers, Justin


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: Darin Crofton on October 27, 2018, 04:55:51 PM
Thank you for the great tutorial! I'm happy to say this was the first upgrade/reel work I've ever done, just completed and the reel is super smooth and working better than before!
I just put it on a rod and had my wife go through the house pulling drag, she thought I was a little crazy, but it worked great! Next up, drag, sleeve and dog upgrade to my Penn 349.
If I can do it, anyone can  ;D  ;D  ;D


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: whalebreath on October 27, 2018, 06:54:56 PM
If I can do it, anyone can....
LOL-that's my motto!


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: Realfunone on October 30, 2018, 06:33:21 PM
What are the measurements of the anti reverse bearing? Mines toast, are the ones that smooth drag sells a good choice ? Thanks


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: redsetta on October 30, 2018, 09:57:34 PM
Quote
...are the ones that smooth drag sells a good choice?
Absolutely


Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: Realfunone on December 23, 2018, 09:38:53 AM
Iím replacing the drags and bearings. Iím not clear about grease or no grease on the roller clutch bearing. Grease inside the sleeve but by greasing the clutch bearing usually will cause failure. Whatís the best practice for this bearing.
 Also what is the recommendation on what is recommended for the other bearings. Do I soak them with brake cleaner than tsi? Remove shields ?

Thanks



Title: Re: Shimano Calcutta 400 - carbontex upgrade
Post by: redsetta on February 19, 2019, 11:57:52 AM
Sorry for the very late reply RFO.
Only use a little bit of light oil (eg Inox) in roller bearings - never grease.
For a casting reel such as this, remove the seals on the spool bearings, clean thoroughly (eg with brake cleaner), then lube and protect with something like TSI301/321.
All others can be packed with marine grease.
Cheers, Justin