AIXAM 500SL15/08/00

VIN xxxxxxxxxxxxxxENGINE 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 portsidedoor

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 mountand 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 withclean 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