Good work! Time to give the elbows a shot of grease before they run dry. In regards to the frame, maybe a combination of Emory cloth strips, sandpaper, and wire wheels would get you where ya want to be. If only to get to rider condition, then I wouldn’t be so concerned about complete removal. Some of that 50 year old paint is still doing its job and is a pain to remove, even with aircraft paintstripper. It still works well as a primer. Some here have just roughed up the surface well with 3m pads and blended the edges and repainted. I just tried some old naval jelly on a pipe and had success in removing the last bit of rust from the surface. Maybe you could lay your hands on some and use it on the rusty parts. Good luck and keep us posted.

Thumbs up on you tank work,

Edit: terrible at explaining this

So I have an M10 bolt which I have tried using as a puller, but it doesn't 'like' being screwd in.. could the thead pitch or something be different?

Hey. Bruce here from Canada. I have some thoughts on painting your frame if you still need them. I have prepped and painted uncountable bike frames and have a process that seems to work well and is not so labour intensive as you might think.

Always interested in pointers!
I'll try to give back when I'm done too

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It looks like you have a flywheel puller which would work for non e-start flywheels, but unfortunately not your application. Take a look at this thread yamaha-enduros.com/index.php/forum/speci...rovised-work-arounds
It looks like folks typically use a slide hammer puller as the armature of electric start models can be a bear to remove.

If you take a look at the AT-1 service manual, Yamaha also indicates you can use a special armature puller bolt, which has a long pin on the end to push it off of the crank. This thread talks about how to make a makeshift system. 64.234.201.42/yamahasnitz/topic.asp?TOPIC_ID=10
Hope that helps!

No picture attached... technically you don't have a flywheel... you need an "armature puller" which is just a long threaded bolt 10mm x 1.25 I think....

Blimey that is a special tool isn't it...... Sounds like I gotta cut the end off a 5mm Allen key and screw it down into the hole

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Yamaha RD350 and RD400 use the same removal procedure... might search RD forums for ideas.