AIXAM 500SL

15/08/00
VIN xxxxxxxxxxxxxx
ENGINE xxxxxxxxxxx
FILTERS
Oil Kubota 15231.4356.0 and HH150-32430 or solid ace s 102001
Fuel Kubota 15853.9917.0
Air Kubota 16667.11080
Heater Plugs NGK YEO11V
Mirror glass Halfords SR90.
Windscreen 7R107V
Wiper blade 22"
Anti-Roll bar rubbers sit in 60mm wide U bolts with 13 mm nuts
Front wheel bearings SKF BAHB 6333 13EA. Disc/hub assy. Comex F090
Front pads set - Aixam Mega 6L065, EBC DP1342
Gearbox Comex D594, 8:1 Reduction
Gearbox Bearings - 2x 6006, 2x 6204/C3, 1x 6304, 1x 6205. Seals
nbr20x40x7as and nbr25x40x7as
Gear oil -1.5 lit Halfords GL5
Engine Oil 15w40
Fan belt Mitsuboshi REMF 1325 N904 231/2
Starter Denso 67980-31151
1st battery Fulmen, then Global Yuasa type 047 32AH, Now Numax 054H, 36
a/h, 180 x 127 x 223 high.
Drive Belt Aixam 3 BP 23 03122008Y or IBC Vario/Twin cam D3211AA 1096

Tyres 145/65 R13 Bridgestone BR 1330. (Revs per mile 988)

Rear wheel bearings SKF Explorer 6005 2 RSH (26mm id 47mm od). Drum assy.
Comex F00 042
Rear shock absorbers Gabriel Z41534
Exhaust 45 mm od 3/4" flex section 550mm long (22") clamps to suit 48 mm
26.08.00 Soundproof Kit
05.09.00 First servce_Cassells
12.12.00 3000 mile service_Cassells
11.03.01 wheel bearing Stbd Front (warranty)
10.06.01 6000 mile service & gear oil
11.10.01 wheel bearing Port Front (fitted by me)
16.11.01 9000 mile service & front disc pads & drive belt
11.01.02 Heater plugs
14.02.02 Exhaust (centre & flexy bit)
27.04 02 12000 mile service & gear oil & handbrake mod & Waxoyl
16.05.02 wheel bearing Stbd Front (Cassells)
19.08.02 15000 mile service & both fuel filters
15.11.02 New Front Studs
15.01.03 18000 mile service & gear oil & electrical connections & battery
21.01.03 Throttle cable repair
23.01.03 Water in fuel
05.02.03 New battery
14 02 03 Exhaust Flexy & undertray

22.03.03 Rear windows tinted

28.03.03 New drive belt
11.04.03 New disc pads & Rain-ex
09.05.03 21000 mile service & waxoyl
10.05.03 Stbd window motor mount
26.06.03 Port window motor mount
03.07.03 Steering flexi-coupling replaced
06.07.03 New fuel filter & throttle cable inner
25.07.03 Full throttle stop adjusted out of action (now by pedal position) &
Battery topped up
07.08.03 MOT (until 14.08.04)
15.08.03 Deep clean & silicone in rear of sills
23.08.03 24000 mile service
04.09.03 Wheels balanced
18.09.03 Aerial mount derusted and temp.probe relocated to above portside
door
02.10.03 renewed.Rain-ex all windows and roof
11.10.03 Throttle cable checked, Head/Sidelights derusted/repaired, port door
silent channel fixed, tickover upped
24.10.03 Brake light switch replaced
08.11.03 Battery removed & serviced
02.12.03 27000 mile service inc. slik 50 in engine & gearbox + WD 40 in CV
boots
24.01.04 Mid-silencer repair & Scotoil
19.02.04 Wheel bearings checked & Brakes & Scotoil

20.02.04 New Stainless exhaust

21.02.04 Boot carpet & soundproofing foam
05.03.04 wheel bearing Stbd Front(Cassells)
15.03.04 Service inc. gear oil and new oil filter and waxoyl
09.04.04 Battery service and primary fuel filter cleaned. Number plates refixed
24.04.04 Floor and fuel pipe entry points sealed,carpets disinfected,dried and
refixed. Steering arms adjusted to centralise wheel.
16.05.04 Handbrake sticking on - lubed both cables and both lever/pivot
assemblies while doing general drum brake service.
19.05.04 All hose clips renewed and radiator unclogged/flushed. New coolant
(25%)
20.05.04 New throttle cable
13.06.04 Overflow bottle added
18.06.04 Primary fuel filter renewed
06.07.04 Serviced
16.07.04 Stbd headlight renewed & handbrake cables lubed
23.07.04 Port headlight renewed & both modified for best siting in apertures, both
lower casings/wing extensions sealed fully
01.08.04 Reversing gearbox bearings replaced following breakdown_Cassells
07.08.04 wheel bearing Port Front & balljoint replaced_Cassells
13.08.04 Part Copper brake pipes and both rear brake cylinders_Cassells
14.08.04 Rear wheel carrier refurbished & soundproofing refixed
01.10.04 Throttle lever pivot fixed using Loctite, Seat movements lubricated,
Drain holes made in Door mirrors.
20.10.04 Anti blind spot mirrors added
21.04.10 Fuel filters cleaned (gummed up) and brakes serviced

27.10.04 Service inc. waxoyl

30.10.04 Stbd carpet underlay replaced, seats & belt mountings derusted &
lubed with Krytex plus cleaning
22.11.04 Both fuel filters replaced, battery serviced and charged, fan belt
adjusted, oil pressure switch cleaned.
23.11.04 Oil changed (looks thin) to try and eliminate warning at tickover.
06.01.05 Springs added to exhaust clamp aft of flexy to draw system up and stop
knocking at rear transverse member
22.01.05 Rainex - all windows + Silicone sealer to n/s wheelwell bit under
carpet and evostik used to glue it back
12.02.05 gearbox failure - towed to Cassels by AA
24.02.05 New gearbox and bearings for variator_BC
25.02.05 Service (brakes and air filter)
28.02.05 Service fuel filters and engine oil
10.03.05 Replaced front engine mounts and removed 2 spacers from variator
25.03.05 Head steady added
29.03.05 Replaced rear engine mount
and freed up rear brakes
31.03.05 Front brake pads replaced
15.04.05 Ignition lock repaired by removing all but 2 tumblers plus Steering Lock
- spare and worn parts stored
23.04.05 Variator cleaned/serviced with new plastic blocks and dry lubed with
graphite
23.04.05 Radio mountings reset and padded to stop noise
13.05.05 Rear wheel bearings replaced and brakes serviced
19.05.05 Gearbox oil changed
25.05.05 New front tyres-Tyrefair

03.06.05 Washer jets and system cleaned out and new fluid added
10.06.05 Radiator leak (worn away at bottom) repaired with Glassfibre
27.07.05 Full service inc. complete dismantle,rebuild of rear brakes with rust
curing and deglazing plus Waxoyl all over
04.08.05 New drive belt
28.09.05 Handbrake cables lubed and freed off Waxoyl of fittings in area
16.11.05 Full service inc. new primary fuel filter, air filter, gear oil, all brakes
serviced, brake and throttle cables oiled, heater plug connections etc cleaned,
battery service, scottoiler spray
03.12.05 wiring short circuit under dash - large positive wire rubbed away on
uninsulated strut.Home via AA
07 to 09.12 05 rebuild of wiring, insulation of everything, all connectors/fuses
disturbed or replaced
06.01.06 New primary fuel filter, insulation of wires and struts on front subframe
under wheelarches to prevent headlight and brake pad warning light shorts
03.02.06 Steering adjusted to straighten wheel and increase toe-in (almost none
and steering was over to Port 20 deg)
16.02.06 New radio fitted and wiring behind dash rerouted.
17.02.06 Rear brakes serviced and cables oiled
06.03.06 Air filter cleaned and windscreen wiper drive lubed
11.03.06 Headlights off - port one given chrome strip to cover bad patch, both
treated to evo stik seals and wax lubricant of adjusters.
21.04.06 Redo of Rainex plus polish of body with special stuff
03.05.06 Full service inc new gear oil, filters and waxoyl, battery service and new
disc pads.
11.05.06 Stbd Balljoint relaced, steering realigned
20.05 06 Throttle cable inner replaced and outer smoothed at ends.

20.06.06 Cracked windscreen superglued as temp. repair

08.07.06 Windscreen replaced - Derrick Pearse. Total Windscreens [243]
7R107V
13.07 06 Outer CV Boots replaced
15.07.06 New windscreen treated with Rainex
20.07.06 Outer CV boots fitted with proper metal straps, Fan belt replaced
07.08.06 Front brake lines renewed, system bled, rear brakes serviced.
13.08.06 New soundproofing
14.08.06 New steering rubber coupling
15.08.06 Variator cleaned/serviced with new plastic blocks and dry lubed with
graphite
29.08.06 Gear oil replaced
22.09.06 Rainex on all windows
27.09.06 Tappets set (to 7 thou), Engine earth, heater plug connections
01.11.06 Full service inc gear oil, filters, tappets 50,000 miles
03.12.06 antifreeze screenwash and leaking sills sealed.
15.12.06 New air filter
23.01.07 Brakes serviced
06.02.07 Scottoiler appied.
22.02.07 Exhaust checked _ RJM
24.02.07 New Drive Belt and front brake inspect/clean
01.04.07 Rainex renewed on all windows
04.04.07 Throttle stop adjusted
18.04.07 Full service inc. all fuel and oil filters, new gear oil, heater plugs, tappets
adjusted, battery charged and all brakes freed/replaced. 53000 miles

31.04.07 Port front wheel bearing replaced.

20.05.07 New rear brake shoes fitted (after removing spring 'adjuster'
mechanism.)
22.05.07 New No. plates fitted.
24.05.07 Waxoyl.
09.06.07 Rear brakes cleaned and handbrake cables lubed/freed
23.06.07 Last bit old old brake pipe renewed and system bled. (only just in time)
05.07.07 Fuel and air filters cleaned
07.07.07 Washer bottle cleaned of bacteria-like deposits. Refilled with
clean rainex plus a few drops of fairy liquid.
14.07.07 Front of car off for crack mending - replaced with bolts (and repaired
with polystyrene cement plus nylon and dope on inside surfaces.
14.09.07 Spare gearbox rebuilt with quality bearings set in chemical metal stored in shed
26.09.07 Full deep service, all filters, all oils, door insides etc.
30.11.07 Front discs and pads renewed.
17.01.08 Port front sidelight fitting shorted. Rerouting of L/H lighting wires to
inside engine bay.
20.01.08 Rear brake service and sidelight bulb holders de-rusted and potted with
Araldite to prevent rust shorting them out.
07.03.08 Service inc. Gear oil. All filters cleaned Scottoiler & cable lube. Sealer
applied to floor&arches.
New brake drums.
25.03.08 Dashboard off, wiring checked and heater serviced.
25.05.08 Rear drums completely dismantled, backplates off, cleaned, rust cured,
lubed and rebuilt.
26.05.08 Front brakes ditto.

07.06.08 Gearbox swapped, cv joints inspected-repacked, front suspension

checked. Battery charged.
20.06.08 Waxoyl of front end.
14.07.08 New inner CV boots and steering boots.
26.07.08 New undertray made.
05.08.08 Outer CV boot replaced and drivers seat fixed
17.08.08 Throttle cable, pedals and hinges oiled and STP added to gearbox
08.09.08 Full Service inc Moly with new engine and gearbox oils, all filters
renewed, waxy cycle lube on brake sliders.
05.10.08 New belt fitted.
21.10.08 fuel heater plumbed in.
27.10.08 fuel heater wired up.
03.11.08 Battery strap modified and new 36ah battery fitted.
15.11.08 Tyres swapped front to back.
19.11.08 Wiper motor shaft repair.
22.12.08 Rainex and polish.
09.02.09 Exhaust checked
15.03.09 Port balljoint and wishbone bolts, Rainex. Stbd side OK
06.04.09 front indicators cleaned out and fixed.
11.04.09. Stbd front wheel bearing, gearbox changed, front brakes serviced.
07. 05.09. Rear brakes serviced
17.05.09. Corroded window strips fixed
21.05.09. Fuel and air filters cleaned
15.06.09. Spare gearbox rebuilt ready to swap.

20.06.09. Gearbox not duff - pulley loose so spring washer added. Variator
cleaned and dry lubed. Gearbox filler fitted with long tube and oil level raised to
2nd gearset level (about 1.5 lit)
21.06.09. Rainex
11.07.09. Brakes and new fastenings for rear bumper
14.07.09. New front tyres
16.07.09. Waxoyl
08.08.09. Rear wiper motor serviced and mounting repaired
10.08.09. New rear tyres plus rear seat locks tightened
11.08.09. Front wiper motor serviced
15.08.09. Floor fixed portside and sealed
30.08.09. New belt
05.09.09. New wear tips for rear variator and new wedges and spring end cups
for front variator
25.09.09. Waxoyl
30.09.09. Service and tyre sealant
08.11.09. Starter motor dismantled/cleaned/serviced
02.12.09. Handbrake cable lubed and brakes checked
17.12.09. Stbd rear bearings repacked and set in bearing fit.
07.02.10. Rear brakes serviced
01.03.10. Head and rocker shaft bolts torqued and tappets set
09.03.10. New Stbd rear wheel bearings, brake service and new front pads.
06.04.10. Serviced
13.04.10. Portside door window motor mount failed. New brackets made and
window tracks wax lubed.

16.05.10. Brakes serviced.

18.06.10 Stbd balljoint replaced plus all wisbone pivot bolts and port side brace
rod bolt replaced (original fell off)
24.06.10. Front Port derust and waxoyl.
25.06.10. All other areas derust and waxoyl.
03.07.10. Repair to stbd subframe extension/front body support. Replacement of
wishbone bolts with HT shoulder screws. Stbd propshaft replaced.
19.07.10 Headlight adjusters/mounts fixed and new undershields made from
fluted plastic
26.07.10. New drive belt
31.07.10. Washer bottle flushed, jets cleaned
07.08.10. Full service, oils changed 11.08.
12.09.10. New antifreeze and repair to thermostat housing (broken bolt).
27.09.10. Brakes serviced.
03.10.10. Main batt/alt/solenoid cable connections cleaned/tightened
25.10.10. Port front wheel bearing replaced, ball joint repacked with new grease.
08.11.10. Gearbox mounting broken (lower lug on flywheel side) welded at work
by Neil. New battery terminal +
Transmission roughness - almost swapped gearbox but found this instead.
13.11.10. Rainex renewed on all outside glass.
03.01.11. Headlamp brackets braced with alloy strip & serviced.
09.01.11. Rear brakes serviced + extra cable springs + dirt shields
17.01.11. New 19 mm nuts for front strut/hub fixings. New Stbd antiroll bar
rubber.
24.01.11. New Port antiroll bar rubber and 2 new mounting brackets.
28.02.11. Stbd front wheelbearing replaced.

06.03.11. Full service, toe-in set to zero.

22.03.11. Rainex and repair to front wiper motor shaft housing.
26.04.11. Boat wax applied.
02.05.11 Rainex plus tyres swapped front to rear.
07.05.11. Rear brakes.
04.06.11. Front variator overhauled. New wedges and spring end plastic wear
plates/bearings.
12.06.11. New gearbox mounting
13.06.11. Port rear brake cylinder replaced and brakes adjusted
20.06.11. New front engine mounts
31.07.11 Brakes - stbd front sticking and stbd rear shoe de-laminating.
05.08.11. New front stbd caliper seal and re-bonded rear stbd shoe.
11.09.11. Wiring under dash checked OK and Battery serviced/charged.
10.10.11 Full service (gear oil and fuel filter OK so not changed), original
handbrake cable extender springs rusted away - job now done by compression
springs on cable ends.
27.10.11. Seats out,serviced,painted, rails fixed, new covers.
29.10.11. Exhaust flexy mended with repair tape/paste.
01.11.11. Rainex.
13.12.11. Wiper motor rebuilt.
16.12:11. Door insides + window motors and mechanisms rebuilt.
02.01.12. Steering column stalk switchgear refurbished.
22.01.12 Aerial connection fixed.
30.01.12. Rainex.
12.02.12. New drive belt (old one breaking up).

13.02.12. Brakes serviced + new front pads + waxoyl front subframe.

16.02.12. Small weld to exhaust manifold.
27.02.12. Service inc. new gear oil GL5
11.03.12. New rear shock absorber on stbd. side and that one swapped for
leaking portside one. New handbrake cable covers/oilers.
12.03.12. Exhaust secured at rear including old engine mount as silencer mount.
07.04.12. Brakes serviced and port rear shock absorber changed.
18.06.12. Brakes serviced, grease into ball joints/track rod ends.
11.07.12. Subframe major derust/waxoyl plus rear end and handbrake mounts,
new brake balancer mounting post.
21.07.12. Front off for derust/waxoyl, brake pads filed/cleaned.
29.07.12 Rear brakes + fuel tank pipe cover leak cured with mastic and hatch
made in floor.
18.08.12 New front brake flexy hoses and wheel cylinders refurbished - brake
sticking problems cured.
08.09.12. Full service
23.09.12. Handbrake adjusted, All lights inspected/serviced, New fibre optic
repeaters for rear ones, new sidelight bulb holders.
25.09.12. New port front wheelbearing
09.10.12. New rear brake shoe pins held in with coil springs, washers and split
pins. Originals breaking up.
14.01.13. Brakes serviced and more Scottoiler
29.01.13. New front pads (old ones worn unevenly due to collapsed hoses last
year)
03.03.13. Rear variator new wear tips (one cracked) inspected for wear, cleaned
tiny amount of wear at circlip of ramp section pulley faces worn to slight S
shape. Front Variator new red blocs, new wear washers and all surfaces

graphited from pencil lead minimum wear of all components. New belt old
one OK teeth and width-wise but cracks on webbing.
04.03.13. New rear brake shoes (offside drum as de-warped as possible but not
perfect) Adjusters to min setting and braced with cable ties.
05.04.13. Full service inc. new oils, filters, fan belt adjusted, Scottoiler, brake
cables/sliders lubed, door hinges and catches.
11.05.13. port track rod end replaced.
25.05.13. new flexy section fitted to exhaust.
26.06.13. starter motor serviced and new braid connected to solenoid, new end
on batt + cable to it and all other wires at front of engine checked/fixed.
To do - heater motor
Next service 90,000 miles.
In Stock - Oil pressure switch, Steering flexy, 1 fuel filter, 4 rear wheel bearings,
1 front wheel bearing, 1 thin shim for front pulley w/washers (spring end plates),
1 old but good rear shock, various old but good variator parts (wear tips, red
blocks, washers)
Notes - the gearbox currently in use is the newer one with new bearings and
more oil with high level breather.
Rear brake lower pivot - small top big bottom.
Flywheel bolts 43ft/lb. Head bolts 31ft/lb. Rocker shaft 8ft/lb.
Tappets 6 thou No1 cyl at rad end. With 1 at tdc+ compression and 1tc mark on
flywheel at top adjust 1 2and 4 tappets when 360 deg adjust 3 tappet (or rotate
with gauge in and feel for best place) To replace rear variator wear tips remove
front variator, belt, chock wheels, in gear, wind inner pulley face aft enough to
make space.
Front wheel bearings last 3yrs