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A Masterclass in Maintenance: A Detailed Guide to Servicing Your Shimano Calcutta 400B

The Shimano Calcutta 400B is a testament to enduring quality and robust engineering in the world of baitcasting reels. A favorite among anglers for its power and reliability, this round reel is a workhorse that, with proper care, can provide a lifetime of service. This comprehensive guide will walk you through a complete, detailed service of your Calcutta 400B, ensuring it remains in peak fighting condition.

Preparation: The Foundation of a Flawless Service

Before embarking on the disassembly of your reel, proper preparation is paramount. Rushing this stage can lead to lost parts and frustration.

Your Workspace: Designate a clean, well-lit area to work. A white towel or a magnetic parts tray is highly recommended. The white background will make small components highly visible, and a magnetic tray will secure any screws or springs that are prone to disappearing.

Essential Tools and Materials:

  • Screwdrivers: A quality set of Phillips and flathead screwdrivers is a must. Ensure they fit the screw heads on your reel perfectly to avoid stripping.
  • Pliers: A pair of needle-nose pliers will be useful for handling small parts.
  • Wrenches: A 10mm wrench will be needed for the handle nut.
  • Schematics: Have the official Shimano Calcutta 400B schematic readily available. This is your roadmap and will be invaluable for identifying parts and their correct orientation. You can typically find this on Shimano’s website or through a quick online search.
  • Cleaning Supplies:
    • Degreaser: A quality, reel-safe degreaser to remove old, gummed-up lubricant.
    • Isopropyl Alcohol: Excellent for cleaning bearings and other sensitive components.
    • Lint-free Cloths and Swabs: For wiping down and cleaning parts.
    • Small Brush: A toothbrush or a small, stiff-bristled brush is perfect for scrubbing gears and other soiled components.
  • Lubricants:
    • Reel Oil: A high-quality, light viscosity oil is essential for bearings and other high-speed components.
    • Reel Grease: A specialized reel grease is necessary for gears and other moving parts that require a more substantial lubricant. A popular and effective choice is Cal’s Universal Reel and Star Drag Grease.
    • Drag Grease: A specialized drag washer grease, such as Cal’s, or Deuthlon, is crucial for ensuring smooth and consistent drag performance.

Pre-Service Inspection: Before you pick up a tool, give your reel a thorough once-over. Check for any obvious signs of damage, corrosion, or malfunction. This will help you focus on any problem areas during the service.

Disassembly: A Methodical Approach

Follow a systematic approach to disassembly, placing parts in the order they are removed on your towel or tray. This will create a logical sequence for reassembly.

1. Handle and Star Drag Removal:

  • Begin by removing the handle nut cap. This can often be done by hand or with a small, flathead screwdriver.
  • Using your 10mm wrench, loosen and remove the handle nut. The handle should now lift off the drive shaft.
  • Slide the star drag off. Be mindful of the two small, curved drag spring washers underneath; they may stick to the bottom of the star drag.

2. Right Side Plate Removal:

  • Locate and loosen the three thumbscrews on the right side plate.
  • Remove the two small screws in the right side plate.
  • Carefully separate the right side plate from the frame. The internal components will now be exposed.

3. Internal Component Disassembly:

  • Main Gear and Drag Stack: Gently lift the main gear off the drive shaft. The drag washers are housed within the main gear. Carefully remove them one by one, paying close attention to their order and orientation. The schematic will be your best friend here. A typical drag stack consists of keyed metal washers, eared carbon washers, and a final metal washer.
  • Pinion Gear and Yoke: The pinion gear and its surrounding yoke will likely lift out along with the main gear. If not, they can be easily removed now. Note the two small yoke springs on top of the yoke.
  • Anti-Reverse System: The Calcutta 400B features a reliable anti-reverse roller bearing. To remove it, gently push it out from the inside of the side plate. The inner tube of the roller bearing will slide off the drive shaft.
  • Drive Shaft: The drive shaft can now be removed from the side plate if so desired.

4. Spool and Left Side Plate:

  • The spool can be easily lifted out of the frame.
  • The left side plate typically does not require extensive disassembly for a standard service unless there is a specific issue with the bearing or the clicker mechanism, or the idler gear.
  • To remove the left side plate assembly, remove two small screws from the inside of the reel. These are the Phillips head screws. Then remove the one slotted screw near the reel seat.
  • The left side plate can now be removed from the reel.

5. Level Wind Assembly:

  • To service the level wind, you will need to remove the pawl cap.
  • Unscrew the pawl cap and carefully remove the pawl.
  • The level wind guide and worm gear can now be accessed for cleaning.

Cleaning and Inspection: The Heart of the Service

With the reel fully disassembled, the crucial process of cleaning and inspection begins.

  • Gears and Metal Parts: Using your degreaser and a small brush, thoroughly clean the main gear, pinion gear, and all other metal components. Remove all traces of old grease and grime. Once clean, wipe them down with a lint-free cloth and set them aside to dry.
  • Bearings: It is generally not recommended to soak bearings in harsh degreasers as this can damage the seals. Instead, clean the exterior of the bearings with a cloth and isopropyl alcohol. A drop of high-quality bearing oil can be applied, and the bearing should be spun to check for smoothness. If a bearing feels gritty or rough after cleaning and oiling, it should be replaced.
  • Drag Washers: If your Calcutta 400B has the stock Dartanium drag washers, they should be wiped clean. If you are upgrading to carbon fiber drag washers (a highly recommended upgrade for improved performance), they will need to be lightly greased with a specialized drag grease like Cal’s or Deuthlon. Apply a thin, even coat to both sides of each washer.
  • Frame and Side Plates: Thoroughly clean the inside and outside of the frame and both side plates. Use a brush and swabs to get into all the nooks and crannies.
  • Level Wind: Clean the worm gear and the pawl with degreaser and a brush. Ensure the worm gear’s grooves are completely free of debris.

Inspection: As you clean each part, inspect it for wear and tear.

  • Gears: Check the teeth of the main and pinion gears for any signs of chipping, rounding, or excessive wear.
  • Drag Washers: Inspect for any glazing or compression.
  • Bearings: Feel for any roughness or play.
  • Pawl: Check the tip of the pawl for wear. A worn pawl can cause the level wind to stick.

Lubrication and Reassembly: Bringing It All Back Together

Proper lubrication is the key to a smooth and long-lasting reel. The general rule is to apply a light coat of grease to gears and moving parts and a drop of oil to bearings and other high-speed components.

1. Level Wind Assembly:

  • Apply a light coat of grease to the worm gear.
  • Place a drop of oil on the pawl and reinsert it into the level wind guide.
  • Screw the pawl cap back on, being careful not to overtighten it.

2. Left Side Plate Assembly:

  • Put the idler gear on the shaft post with a drop of oil. Oil the teeth of the idler with a light oil. Add the small brass washer on top of the idler gear.
  • Install the left side plate assembly into the frame of the reel.

3. Right Side Plate Assembly:

  • Drive Shaft: Apply a light coat of grease to the drive shaft and reinsert it into the side plate.
  • Anti-Reverse System: Lightly oil the anti-reverse roller bearing and its inner tube. Slide the inner tube back onto the drive shaft and press the roller bearing back into its housing in the side plate.
  • Pinion Gear and Yoke: Apply a light coat of grease to the pinion gear and place it in the yoke. Reinstall the two yoke springs.
  • Drag Stack and Main Gear: If you have greased your carbon fiber drag washers, reassemble the drag stack in the correct order within the main gear. Apply a generous coat of grease to the teeth of the main gear.
  • Installation: Carefully place the main gear and drag stack assembly back onto the drive shaft, ensuring it meshes correctly with the pinion gear.

4. Final Assembly:

  • Spool: Place a drop of oil on the spool shaft on both ends and where the pinion gear runs. Reinsert the spool into the frame.
  • Connecting the Side Plate: Carefully align the right side plate with the frame and press them together. The side plate should sit flush.
  • Thumbscrews: Tighten the three thumbscrews on the right side plate.
  • Tighten 2 Phillips head screws in right side plate.
  • Star Drag and Handle: Reinstall the two curved drag spring washers (in a “()()” orientation), followed by the star drag. Screw on the handle nut, and then reattach the handle nut cap.

Final Checks and Adjustments

With your Shimano Calcutta 400B reassembled, perform a few final checks:

  • Handle: The handle should turn smoothly and without any binding.
  • Free Spool: Engage the free spool and give the spool a spin. It should spin freely and for an extended period.
  • Drag: Tighten the star drag and pull line from the spool. The drag should be smooth and consistent.
  • Level Wind: Turn the handle and ensure the level wind travels back and forth across the spool without any hesitation.

By following this detailed guide, you have not only performed a routine service but have also gained a deeper understanding of the inner workings of your Shimano Calcutta 400B. Regular, thorough maintenance will ensure that this legendary reel continues to be a trusted companion on all your fishing adventures.