penn 525 mag T rebuild - 2/14/2010

    penn 525 mag T rebuild - 2/14/2010

    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.…ts/schematics/525magt.pdf

    and here is our reel.

    start by removing the left side plate screws (key #'s 32 and 110).

    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).

    remove the left side ring (key #28).

    remove the left side plate (key #27).

    here's an inside view of the left side plate, showing the magnet.

    remove the spool assembly (key #29L).

    here's a quick glance inside the frame (key #183).

    we're going to take a moment to clean up the frame a little.

    now, back to the spool. remove the spool spindle (key #71L).

    remove the clutch plate retainer (key #71C).

    remove the clutch plate (key #71B).

    remove the right spool bearing (key #55). it measures 0.185 x 0.375 x 0.125 inches.

    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

    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.

    install the right spool bearing (key #55).

    install the clutch plate (key #71B).

    install the clutch plate retainer (key #71C). you know, that retaining ring doesn't look like it's got a very good grip.

    let's flip the clutch plate over and reinstall the retainer.

    there, that looks like the ring has a better grip.

    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.

    remove the left side spool bearing (key #55). this bearing also measures 0.185 x 0.375 x 0.125 inches.

    clean, lube and reinstall this bearing (key #55) in the same way.

    before you install the click ratchet (key #81), match up the grooves.

    install the spool spindle (key #71L).

    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!

    install the spool assembly (key #29L).

    take a moment to grease the screw holes.

    install the left side plate (key #27).

    install the left side ring (key #28).

    install the two long left side plate screws (key #32) and the one short left side plate screw (key #110).

    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.

    now for the right side plate. remove the handle lock screw (key #32A).

    remove the handle lock (key #110A).

    remove the handle nut (key #23) using a 7/16ths wrench.

    remove the handle (key #24).

    remove the tension spring washer (key #8). i usually throw these away. they tend to cause corrosion.

    remove the star drag (key #10).

    remove the tension spring washer (key #18).

    remove the two right side plate screws (key #32).

    push the eccentric lever (key #21) straight up.

    remove the right side ring (key #2).

    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).

    remove the right side plate screw (key #39S).

    remove the two lower right side plate screws (key #46).

    remove the right side plate assembly (key #1).

    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.

    remove the clutch shaft (key #98S).

    remove the entire drag stack as a unit (key #'s 5, 6 and 7C).

    remove the fiber washer (key #4).

    remove the ratchet spacer (key #98R).

    remove the two clutch springs (key #18B).

    remove the pinion gear (key #13) and the pinion yoke (key #12) as a unit.

    remove the eccentric jack (key #11).

    remove the two bearing retainer screws (key #63).

    remove the gear stud (key #134) and bearing (key #20A) as a unit. this bearing measures 8 x 16 x 5mm.

    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).

    remove the shields of this bearing (key #20A), pack it with grease and replace the shields.

    reinstall the packed bearing (key #20A) and the bearing screw (key #121).

    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.

    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.

    ok, we are NOW ready to put everything back together.

    install the gear stud (key #134), bearing (key #20A) and screw (key #121) as a unit.

    install the bearing retainer (key #173).

    install the bearing retainer screws (key #63).

    install the eccentric jack (key #11).

    install the pinion gear (key #13) and pinion yoke (key #12) as a unit.

    install the clutch springs (key #18B).

    install the ratchet spacer (key #98R).

    we are going to replace the fiber washer (key #4) with a penn ht-100 #6-113 drag washer.

    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.

    install the main gear (key #5).

    slap a thick coat of cal's grease on the three drag washers (key #6).

    install the drag washers (key #6) alternating with the metal washers (key #7C) and the clutch shaft (key #98S).

    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.

    put a small bead of grease in the screw holes of the frame (key #183).

    flip the eccentric lever (key #21) forward and install the right main side plate (key #1).

    install the two lower right side plate screws (key #46).

    install the small right side plate screw (key #39S).

    move the eccentric lever (key #21) to the center and install the right side ring (key #2).

    install the two right side plate screws (key #32).

    install the tension spring (key #18).

    install the star drag (key #10) and turn it down until it clears the shoulders of the gear stud (key #134).

    remember the tension spring washer (key #8)? all it does is cause corrosion, so we are going to throw it away.

    install the handle (key #24).

    install the handle nut (key #23).

    install the handle nut lock cap (key #110A).

    install the handle lock screw (key #32A).

    install the spool assembly (key #29L).

    install the left side plate (key #27) and left side ring (key #28).

    install the left side plate screws (key #'s 32 and 110).

    congratulations, you're done!

    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.

    ok, now we're done!
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