QuestionSorry about the brand, 2004 LT80 has sat for a few months and would not start.
The battery was replaced, and now the starter relay just clicks when starter is
pushed.
Answerhttp://houseofmotorcycles.bikebandit.com/suzuki-atv-lt80k3-2003/o/m6410
I didn't see a listing for 2004...
If the battery is fully charged and passes a load test, check the power in and out of the solenoid on both primary and secondary connections. If power is going out to the starter motor, then the starter or starter clutch are probably having a problem. You can generally jumper across the two big wires with pliers or a screwdriver to run power direct to the starter motor. If that does work, then there is a starter relay problem internally and/or the circuit to the button on the handlebars is defective.
If the button does elicit a click from the starter solenoid, the button wiring is probably okay, however. Some starter buttons just ground the line to the relay and some just complete a circuit back to the solenoid. I have no idea of which way yours is wired. In looking at the electrical illustrations selection, it looks like the relay is a small encapsulated type which may be impossible to disassemble and inspect for defects. You may just have to replace it with a new one. Just be sure that the motor turns over okay and that the battery is fully charged.
In off-road applications, you need to keep an eye on all electrical connectors and ground wiring which can get corroded due to exposure to the elements and washing.
Looks like there are lots of parts on Ebay for this bike, so maybe there are some inherent problems with the starter motor or solenoids.
FYI
If you let old fuel sit in the carb for more than a couple of weeks, the idle jet will probably plug up, so that when you get the starter problem fixed, it may still not start up due to blocked fuel passages.
Bill MrHonda Silver
