Pier Fishing in California

Resources :: Reel Rebuilds

Shimano Charter Special Rebuild

By Alan Tani

I’ve had several requests to post a thread on this reel. Last month I had two come through, so I shot some photos. First, the schematic from Shimano....

http://fish.shimano.com/media/fishing/SAC/techdocs/en/Conventional/TR_2000LD-ARB_v1_m56577569830570239.pdf

Here’s a stock Charter Special. These reels had seen several years of service and were in pretty bad shape. The handle turned easily on one but was rough on the other. Freespool time on one was only a few seconds, but that is par for most levelwind reels. The freespool was zero on the other. Both reels had pretty jumpy drags, even at a light setting. Not a good thing for salmon.

Shimano Charter Special Reel

The first thing to come off is the lever assembly, including the pre-program dial (key #115), the dial spring (key #82), the lever shaft body and “O” seal (keys #116 and 10), the drag control lever (key #117) and the lever thrust ring (key #84).

Shimano Charter Special Reel

Remove the lever quadrant (key #121) and screws (keys #19, 20 and 21).

Shimano Charter Special Reel

Back out the five side plate screws (key #122) and remove the right side plate as a unit.

Shimano Charter Special Reel

Remove the spool assembly as a unit.

Shimano Charter Special Reel

Note the wear marks on the right side of the spool.

Shimano Charter Special Reel

It is a common problem for these graphite frames to “swell.” I use a Dremel and the cutting bit #117 to cut away at the inside of the graphite frame, just enough so that the spool doesn’t rub.

Dremel Bits

Add a little grease to the metal clicker assembly (keys #140 and 209).

Shimano Charter Special Reel

Remove the spool cap and drag pressure plate as a unit. Note the reverse threads.

Shimano Charter Special Reel

Here’s a photo of the original canvas drag washer next to a Penn HT-100 drag washer (part #6-5600). Use a Dremel to hand cut the inside hole to match the stock canvas Shimano washer.

Shimano Charter Special Reel

Back out the four click gear screws (key #135), remove the click gear (key # 134) and the main shaft assembly.

Shimano Charter Special Reel Shimano Charter Special Reel

The shields of the three spool bearings can be removed and you can see the dried grease inside.

Shimano Charter Special Reel

After cleaning out the grease with carb cleaner and compressed air, the bearings can be lubed with Corrosion X or Reel X.

Shimano Charter Special Reel

Switching out thin pre-load washers (bellevilles) for thicker ones will ramp up the drag pressure more quickly and give you a higher drag at strike before you lose freespool. The thin preload washer B’s (key #44) on the right will be switched out for the thicker preload washers from the Shimano TLD 20/30 two speed reels (part # tt-0040A). the orientation of these belleville pressure washers remains “()”.

Shimano Charter Special Reel

Interestingly, the thickness of the stack of thin bellevilles....

Shimano Charter Special Reel

is about the same as the thick bellevilles....

Shimano Charter Special Reel

Here is the reassembled washer stack with bearing. Reinstall the spool shaft assembly, the click gear, the two right side spool bearings (keys #213) and spring (key #37).

Shimano Charter Special Reel

Those of you that prefer a dry drag can either re-install a new canvas washer (part #tld-0129) or use a the Penn HT-100 without grease. My preference remains to grease this washer using Shimano or Cal’s drag grease, applying a thick coat to both sides of the drag washer.

Shimano Charter Special Reel

Install the gooped up washer.

Shimano Charter Special Reel

Wipe off all the excess drag grease until drag washer basically looks dry.

Shimano Charter Special Reel

Now, just a side bar comment. note the rubber gasket of the spool cap....

Shimano Charter Special Reel

and the metal lip on the drag pressure plate assembly.

Shimano Charter Special Reel

When the drag lever is at strike and the reel is engaged, this metal lip mates up with the rubber gasket and seals up the drag chamber to keep water out. The take home message is this. rinsed off your Shimano lever drag reels in the “strike” position. All other lever drag reels should be rinsed in “free.”

Here’s an example in the second reel that was probably rinsed with the lever in the “free” position. Note the rust in the right spool bearings.

Shimano Charter Special Reel

Install the pressure plate assembly.

Shimano Charter Special Reel

Install the spool cap and pinion gear.

Shimano Charter Special Reel

Install cross pin B (key #50) and place the spool assembly back into the frame. The spool should slide easily back into the frame.

IF THE SPOOL DOES NOT SLIDE EASILY BACK INTO THE FRAME, ROTATE THE SPOOL SHAFT 180 DEGREES AND TRY AGAIN.

This works. i have no frickin’ idea why!

Now, this reel felt like a coffee grinder when you turned the handle. This rusted right main side plate bearing (key #212) is the reason. To get the to bearing, you have to remove the handle.

Shimano Charter Special Reel

Remove the handle lock screw (key #1), the handle lock (key #2), the handle nut (key #3), the gear shaft shield (key #5), the gear shaft thrust washer (key #6) and the main gear (key #8). The dog (key #26) and the brake collar (key #190) will fall out as well.

Shimano Charter Special Reel

Pry out the right side plate bearing.

Shimano Charter Special Reel Shimano Charter Special Reel

The old bearing was too badly rusted, so I pulled out a new one....

Shimano Charter Special Reel

and packed it with heavy grease.

Shimano Charter Special Reel

Reinstall the new bearing and dog.

Shimano Charter Special Reel

Install the main gear, the rotate the dog clockwise until the gear “drops” into place.

Shimano Charter Special Reel

Install the handle assembly.

Shimano Charter Special Reel

Install the brake collar.

Shimano Charter Special Reel

Reinstall the right side plate.

Shimano Charter Special Reel

Install the quadrant.

Shimano Charter Special Reel

Install the lever and pre-set dial. Make sure the lever is in the free position and drop the lever shaft body into the lever so that they mate up.

Shimano Charter Special Reel

There are several handle options available. Be creative!

Shimano Charter Special Reel Shimano Charter Special Reel

The spools of both reels will now spin easily. Both of these reels have only 5 seconds of freespool, but that is because of levelwind mechanism. Without the levelwind assembly, the spools probably would spin for 30 seconds. Both now have a max drag at strike of 15 pounds before losing freespool. And both have a smooth drag from 1 pound up to 15 pounds. The total time required for service, including time to clean out the bearings, was an hour.