Shimano Tyrnos 20 Problem

[sparksey]

I am just calling out to the brains trust for help. I have a Tyrnos 20 on my bench that the customer says is very stiff to wind. After quizzing him it appears that he has been increasing the preprogram dial whilst in gear fighting a fish to give him more drag. Why he didn't just go over the button is beyond me.

I have replaced the pinion gear, pinion bearing, lever shaft body and the bearings on the spool but the problem remains.  With the reel in gear, increasing the drag to about 4kg makes it very stiff to wind and more drag results in more stiffness. I guess my next option is to replace the spool shaft?

I have spent hours chasing this problem without success. Any help would be appreciated.