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Note - Exhaust Flange nut torque spec's:

       | Front: 14 ftlbs
       | Rear:  17 ftlbs 

Yamaha Speedstar Drags Exhaust Installation

Note: It is very important to get the exhaust pipe flanges up squarely against their head exhaust mating surfaces, and to snug the flange nuts down evenly moving back and forth between them until reaching the specified torque. It is very easy to get them unevenly seated if you just tight one nut to it's spec at a time. and even though the nuts will tighten to their spec this way, the flanges can still be unevenly seated.

  1. Disconnect the oxygen sensor wires at the electrical connectors about 9 inches from the sensor itself.
  2. Disconnect the EXUP cables at the pipes.
  3. Remove the 2 into 1 section of the pipes. Then remove the front and rear headers.
  4. After you get the stock pipes off, and before you do anything else, change your transfer case fluid. You'll never get another chance to do this with no pipes on the bike.
  5. Install the oxygen sensor on the SpeedStars.
  6. Disconnect the exup cables at the upper connection.
  7. Now you're ready to install the SpeedStars. Get a helper to help hold the pipes in place.
  8. Put the front pipe on first. Header nuts just finger tight.
  9. For the rear pipe you have to slip in the cross-over tube and get it on the header bolts at the same time. It's tricky. Don't mash the cross-over grommet. Again, Header nuts just finger tight.
  10. Loosen the bolts on the frame that attach to the connection arm to the rear of both pipes.
  11. Get both bolts on the rear connection arm started about 5 or 6 threads (this is the most awkward part of the installation). Then tighten the bolts on the frame.
  12. Tighten the front header nuts.
  13. Tighten the rear header nuts. You won't be able to get a socket on the left one very well. Tighten it first as best you can, then tighten the right one. That will put enough stress on the left one.
  14. Tighten the two bolts on the rear connection arm.
  15. Re-connect the oxygen sensor wires.
  16. Tighten the worm drive on the hose clamp at the cross-over (not too tight).
  17. Don't start up the bike until you clean and polish the newly installed pipes. You have to get any oil from your fingerprints off before the pipes get hot.

Thanks "srtrend"!

Reference: http://forums.delphiforums.com/starroadliner/messages?msg=8148.32