Hey guys got a tough one that I can't figure out.

 

It's an Abu Garcia Ambassadeur Five Star Round Reel. When casting there is a fairly loud clicking sound which doesn't seem to effect the cast itself but it is annoying. You don't hear any noise on the retrieve. I've completely disassembled, cleaned and re-lubed but still have the noise on the cast. It's not a whining sound like a bearing just a clicking sound. Any ideas? Thanks.

Just a guess but you may have some worn parts in the clutch assembly, this would keep the pinion from complete disengagement, hard to say without seeing it. You may want to check your brake, the surface the little rollers roll on or if the rollers are cracked. Hard to say without seeing it, but that is where I would start. 

only thing on that reel that comes into play during casting is the bearing packs (in the spool), the centrifical brakes (white blocks), and idler/worm gears to drive the line carriage.

Have you checked both bearings for the noise? Are your centrifical blocks lose enough to come off? Have you checked the white idler gear under the palming side plate for a bad tooth? Have you checked the worm gear as the pawl passes over it, could there be a nick in the slots.

The last resort would be check the engagement tips of the brake block ring and pinion engagement slots, see if there is some wear/rubbing, the pinion yoke may not be lifting the pinion/base (w/engagment slots) far enough to clear those engagement tips. As the spool spins they could be hit by the pinion engagement slots..
Just a couple of place to look at....

Good luck & Tight Lines! 

Could be the "pawl"..., that's the piece under the levelwind . It probably is wearing and not making full contact with the pawl gear. If it's that it's an easy inexpensive fix.

only thing on that reel that comes into play during casting is the bearing packs (in the spool), the centrifical brakes (white blocks), and idler/worm gears to drive the line carriage.

Have you checked both bearings for the noise? Are your centrifical blocks lose enough to come off? Have you checked the white idler gear under the palming side plate for a bad tooth? Have you checked the worm gear as the pawl passes over it, could there be a nick in the slots.

The last resort would be check the engagement tips of the brake block ring and pinion engagement slots, see if there is some wear/rubbing, the pinion yoke may not be lifting the pinion/base (w/engagment slots) far enough to clear those engagement tips. As the spool spins they could be hit by the pinion engagement slots..

Just a couple of place to look at....

Good luck & Tight Lines! 

Thanks RM. I knew you would respond.

Thanks guys for giving me some ideas to look at.

only thing on that reel that comes into play during casting is the bearing packs (in the spool), the centrifical brakes (white blocks), and idler/worm gears to drive the line carriage.

Have you checked both bearings for the noise? Are your centrifical blocks lose enough to come off? Have you checked the white idler gear under the palming side plate for a bad tooth? Have you checked the worm gear as the pawl passes over it, could there be a nick in the slots.

The last resort would be check the engagement tips of the brake block ring and pinion engagement slots, see if there is some wear/rubbing, the pinion yoke may not be lifting the pinion/base (w/engagment slots) far enough to clear those engagement tips. As the spool spins they could be hit by the pinion engagement slots..

Just a couple of place to look at....

Good luck & Tight Lines! 

X2.