Reefman, normally when a bearing goes, you get some advanced warning - the knocking and grinding. This wasn't like that. Literally the fish was diving against a tight drag, the angler was palming a bit and the spool stopped turning. It didn't slow down or become sticky, it just stopped dead. I couldn't even turn it by hand.
When we opened it up the spool bushing had melted - I would think this is because there was play between the shaft and the spool causing a hot spot. I think this was symptomatic though.
The real problem appeared to be the cast metal "hole" that the main shaft goes through in the body. The top of this had sheared off meaning that the shaft could flex. As a result it lifted the drive gear. I guess that over some time the slack created grinding paste and this eventually stopped the gear from turning. Not sure if this is endemic or a once off fault.
Seeing as my kit gets used and abused regularly with just a quick rinse at the end of the day and a spray with WD-40, I cannot guess what happened when, as the reel hadn't been opened for some time.
In defence of the reel, the drag was still smooth and my youngest is bleak at it being tossed. (he is now busy destroying a Lethal 40!)
We are still searching for the ultimate yellowtail casting reel. (300m of 30lb braid, 5:1 or faster, lightweight, strong and smooth drag, well built, etc).
Currently we use: Lethal 40, Exceler 4000, Opus Plus 5000, Sustain 5000, Stradic 5000, Stradic 8000, Stella 5000, Cabo 40, Abu Soron, Daiwa Emblem, Penn Battle.
Stradic 5 is the best casting and until recently the Stradic 8000 was the best for pulling fish - but it has developed a noise recently when retrieving.
