From time to time, someone on this site experiences a problem with the paint that they have applied to their exhaust. I've recently removed, repainted and re-installed the stock exhaust system on my '89 GS. I used KRYLON brand BBQ & Grill hi-temp paint and it has turned out perfectly. I don't think paint brand itself mattered as much as one very key element....PREPARATION. First of all, I used NO solvents or chemicals. It seems that some of the blistering and adhering problems stem from the fact that perhaps some minute traces of paint remover residue was still present on the surface to be painted. I used nothing but #100 sandpaper and 000 steel wool. After I had gotten the surface clean and smooth, I wiped it all down with a clean, lint-free cloth. Several times. Then I hung the exhaust assembly with a wire and sprayed multiple, very light coats, of the KRYLON paint. Then I didn't touch it for two days. After re-installing it on the bike, I "cooked" the paint for ten minutes at idle. The following day, I rode it reasonably hard, paint and exhaust were perfect. Subsequent to the repainting, further hard and hot rides have yielded no blistering, discoloring or peeling.

I think the key here is  NOT to use chemicals in removing the old paint and /or rust. And make sure the surface is as clean as possible for the paint to adhere to it.

Quote from: pnaberhausI used KRYLON brand BBQ & Grill hi-temp paint and it has turned out perfectly..

I use that stuff to paint old military surplus rifles.. It does the job wonderfully..

On a related note, I just repainted my very rusty exhaust.  I hit it with a heavy wire brush on a drill to get the old rust off... it was a lot of work as the rust had "travelled" under the existing paint.  Anywho, I buzzed it down to bare metal, washed it, and cooked it with a propane torch to make sure it was ABSOLUTELY dry.

Then I hung it from a tree and did a base coat(s) with Rustolem BBQ paint, and finished it off with Krylon BBQ paint.  I trust Rustoleum to protect the metal better, which is why i put it on first.  Krylon looks nicer, though, so I finished with that.

Like pnaberhaus said, many LIGHT coats is the key. Patience, patience, patience!! 

I used header paint (duplicolor I think) on my mustangs headers, applied about 3 light coats allowing it to dry for at least an hour between coats, then let it dry for a day, then I baked it at 500 degrees F for 6 hours in a kiln. It looks really good and hsn't peeled or chipped from the heat, but it dose scratch and chip really easilly from tools hitting it. how is the BBQ paint when it comes to scratches?

Since this thread has resurfaced, perhaps an update is in order. Here we are a year later, and the paint on the pipes still looks good.  No rust, no discoloration, no flaking, no crazing, no wrinkling It should be noted however, that although I've ridden through the occasional puddle of water, the bike hasn't been in the rain and is kept in the garage. If you keep your GS stored outside, if it gets knocked over and the pipes get scuffed/scratched , or if you drop wrenches, screwdrivers, or otherwise compromise the paint surface, "you're results may vary" (as the saying goes).

Glad to hear it's held up well.  I can say that the Rustoleum stuff is not very durable; it's been about six months since I did mine and it has a lot of small scratches on the headers presumably from road debris.  I think I'll try the Krylon when I re-do it. 

Strange.  The stock headers on my 99 are still black.  The bike is kept outside.

The factory finish on the pipes of my '89 GS were fine until I inadvertantly overfilled my battery a couple years ago. Out the vent tube the contents went, nicely blown over the pipe/muffler connection in an artistic, wind inspired pattern of acid etched streaks Shortly thereafter, the pretty nice white streaks turned into an attractive reddish-brown patina, just the ticket to put you in mind of, say, a 25 year old farm implement. KRYLON BBQ paint, sandpaper, steel wool and a couple hours prepping and painting put it back to its original appearance.

that paint didnt hold up for me,

every day ridding, rain and all. plus 10k miles on so i guess considerign that it's fine

but i may just have mine power coated crome this winter after the turbo flange i have is welded in