Barricade - Yamaha FZ-16 (2009) - Midnight Black

Thread Starter #556


Honoured Member
Sep 11, 2009
March 2022 - Exhaust Painting

Exhaust has been a sore part on the bike with the faded, rusty appearance.

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Bought in September 2021 and painted in March 2022, thanks to commitments, laziness and back pain. Nippon Ryo Pylac 1000 Heat-Resistant Black Spray Can MRP ₹ 487.00, got ₹ 195.00 discount with effective price ₹ 292.00. Got from Santha Paint House.

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Removal. One nut ant bolt near rear foot rest.

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One bolt on either side of the exhaust underbelly.

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Two nuts on engine head.

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These two nuts are difficult to access. Only the 1/4 inch drive would fit (maybe the 3/8 too). 1/4 to 3/8 to 1/2 adaptation vs direct 1/2 inch drive [lol]

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With everything unfastened and some wiggle, the exhaust comes off. Can be pulled out with some twisty moves.

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Cover up the exhaust port.

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Removed the covers.

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Condition of exhaust. Dirt + tar + rust. No holes.

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Started off with diesel and wire brushes.

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Then with stolen wire sponge and vim liquid.

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Ended up wet sanding with 400 & 800 water paper.

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Once more vim liquid.

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Painted two coats with 30 min gap.

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Left to bake in sun for 3-4 hours.

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New exhaust cover.

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Old broken cover.

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Old vs new.

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Forgot to buy rubber grommets and spacers (again). Reused the old ones.

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Ready to install.

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The incomplete look. Electric bikes would sorely miss those.

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Positioned before install. Chances of scratching is high, reason for installing the cover later.

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Exhaust Pipe Gasket - 21C-E4613-00 - ₹ 22.00
Recommended replacing every time refitting the exhaust, but not mandatory.

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Installed the gasket.

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Hook up the exhaust port first

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and align and install the rear bolt.

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Install rest of the bolts and and tighten up and done.

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Old gasket and carbon build-up.

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Old ones were rusted, so bought new ones

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and replaced later.

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There would be fumes and unpleasant smell for some days till the paint bakes and settles down.
Thread Starter #559


Honoured Member
Sep 11, 2009
March 2022 - New Handle Grips

Dirt in grip, prompted replacement. Last changed in 2017.

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New grips.
Handle Grip RH - 21C-F6240-000 - ₹ 57.00
Handle Grip LH - 21C-F6241-000 - ₹ 42.00

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Rust inside RH grip.

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Cleaned and off.

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Installed new one. Comparing old with new.

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LH grip still looked new. New one had length difference. I can't make out old and new.

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Installed. Getting it out is a bit tricky. Usually, would apply a thin film of oil for rust prevention, which causes a little bit of free rotation, but when the bar end is installed, it would be tight between the switchgear and won't rotate unless you wanna force it.

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Bar end weights. Painted them. I liked their rounded edge compared to original Bajaj ones, so keeping them.

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All done.

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