How to Deactivate the Parking Brake Sensor on a Raptor 660

Yamaha Raptor 660 sport ATVs built before 2005 were equipped with a parking brake sensor switch that limits the engine to a maximum of 2,000 rpm while the parking brake is engaged. Though the sensor switch provides a valuable safety measure, it is very sensitive to vibration and extreme shock, which may trip the sensor and limit the engine's performance midrace. To avoid this problem, many Raptor owners disable the parking brake sensor switch, which is little more than a normally open switch attached to the clutch lever perch. Although the switch wiring can be cut at the perch, removing the switch entirely is a simple and much better option.

Things You'll Need

• 10 mm socket
• Socket wrench
• 5 mm Allen wrench
• Razor blade
• Phillips screwdriver
• Plastic cable tie
• Torque wrench

Instructions

1. Park the ATV on a flat, level work surface.

2. Unplug the headlight bulb socket from the rear of the left headlight unit, then remove the left headlight unit, using a 10 mm socket and a socket wrench. Remove the front grille panel, using a 5 mm Allen wrench.

3. Cut the plastic cable tie attaching the parking brake switch wiring and the left handlebar switch assembly wiring to the handlebar, using a razor blade. Follow the parking brake switch wiring from the clutch lever perch to the white connector behind the left side of the radiator.

4. Remove the cable retaining clip attaching the parking brake switch wiring to the left side of the steering stem, using a Phillips screwdriver. Unplug the switch wiring from the white connector near the radiator.

5. Push down on the lock tab at the top of the parking brake switch connector, then pull the switch out of the clutch lever perch. Pull the switch wiring up and out from between the handlebar and the front fender.

6. Secure the left handlebar switch assembly wiring to the handlebar with a new plastic cable tie.

7. Reinstall the front grille panel and the left headlight unit onto the ATV. Tighten the headlight mounting bolts to 5.1 foot-pounds with a torque wrench. Plug the headlight bulb socket onto the rear of the left headlight assembly.

Tips & Warnings

• Removing the parking brake sensor switch entirely, instead of cutting it, will allow you to reinstall the switch when it is needed again.

References

• 2003 Yamaha YFM660RN/RNC Service Manual; Yamaha Motor Corp.