Zillon SV TW; Cannot get it reassembled correctly

[Houndfish]

Hi,

So after a dozen tries, I have to share my shame and ask for help. I have a Zillion SV TW 9.1. I got it when they first came out and have used it a few times a week since then. A week or so ago I noticed it was making a soft "whooshing" noise on the retrieve when retrieved under load. It sounded like a piece of paper in a fan blade, but much softer. Having successfully taken a few other Dawia reels apart to replace the drag washers, I though I would crack the Zillion open and see if there was an obvious cause.

I stripped down the reel to the bare drive shaft and didn't find anything broken or any foreign matter in there. I went to reassemble it and when holding it all back together, everything ran fine. But when everything was tightened down, the handle would not engage the spool, nor would it move the clutch lever. I took everything apart again and now I cant even get it to work loosely assembled .I was following the parts diagram and everything seems accounted for and in the right spot.

Here are the pictures of it stripped almost all the way down;





Is there anything obviously wrong that is jumping out at anyone? Below is the parts breakdown for reference.
http://www.daiwa.com/us/service/manuals ... 16H_SH.pdf

I would love any advice or suggestions on what to try. If I must I am willing to send it out to a pro, but I would love to fix it myself, but more so I want to figure out what I am doing wrong.

Thanks!

[IlliniDawg01]

Is the silver anti reverse gear in the last picture on upside down?

DaveJ

[Houndfish]

I have tried it both ways, but I will give it a go again now.

[Houndfish]

One problem solved; the spool would not engage because the bearing pin on the spool had fallen out. I keep my parts in an 3600 box when I am working on a reel, but it was nowhere to be found. Fortunately I had ordered some spares the last time I bought after market bearings.

But now a new problem. I don't even know how I did this, but when fully reassembled, the handle cranks backwards. I don't even know how that could happen, but here we are.

[JDLaman]

Sounds like the roller clutch bearing in the side plate is in backwards. Pop it out, flip it over and reinstall it. You should be good to go then.

[Houndfish]

That sounds like it! I will try in a second.

[Houndfish]

Ok! The handle now moves in the correct direction!

Last remaining issue is the clutch bar not engaging. The AR Ratchet is currently installed opposite of how it is shown in this picture;

I have tried it both ways and neither seem to work out.

[PikeRoadBassn]

Ok! The handle now moves in the correct direction!

Last remaining issue is the clutch bar not engaging. The AR Ratchet is currently installed opposite of how it is shown in this picture;

I have tried it both ways and neither seem to work out.

The AR ratchet is installed properly via your picture. Ensure that the clutch kick lever is moving completely forward while the reel is down. If it is not, then something is preventing full movement, such as too dry, piece of trash etc.

[Houndfish]

The clutch trip lever (part 43) seems to be at the full limit of it's movement, but spinning the drive shaft in this state of disassembly does not trip the lever with the AR Ratchet in either orientation.

Also, thanks you all for the help so far, I really appreciate it.

[IlliniDawg01]

The clutch trip lever (part 43) seems to be at the full limit of it's movement, but spinning the drive shaft in this state of disassembly does not trip the lever with the AR Ratchet in either orientation.

Also, thanks you all for the help so far, I really appreciate it.

Flip that big silver gear back over. That was my mistake. I was thinking that was an antireverse dog, but that gear engages the clutch. My bad.

DaveJ

[Houndfish]

Thanks! It's back together and in the process I learned a lot about reels, so thats a win.

However, the bad news is that the noise I was originally trying to chase down is still there, so the reel is going off for service in any case.

[DirtyD64]

Check around your spool and frame. I had a tiny piece of line causing this once on a reel, cleaned multiple times and don't know how I missed it. Was an embarrassingly simple issue, either way I am sure they will know what to do.

[y2k88]

Have you tried turning the handle when the spool is left out?
Could it be the pinion bearing?
Could it be the anti-reverse bearing?

[Houndfish]

I had initially thought it was some kind of debris in the gearing, but I have had it apart enough times now that I am (reasonably) confident that there is nothing in there. The noise only happens when the reel is retrieving under a load, and not every time, so it is hard to troubleshoot as I cannot make the sound happen reliably. One of the times I had the reel apart I inspected and listened to each bearing and none of them seemed to be out of the ordinary.

[mark poulson]

If it only makes noise sometimes when it's under load, maybe it's a problem in the drag stack.