Hello, I have an 01 LT80. The starter went bad and I got it replaced. There is no one close who will work on them so I did it myself. When I got it switched out the relay would only click. Switched out the relay and nothing. Had issue with new starter wires connection from the relay, but jeri-rigged that. Everything worked fine for a week then my boy was riding, got off to get some water....and nothing. No click no sound nothing. Ordered another relay and still nothing. I checked with tester light and have power to relay, but nothing out. I am at a loss. There is one fuse it the thing next to the relay but it is fine. Please help, with all this stuff going on this is the only activity my boy can do. Thank you in advance

 

Here is the wiring diagram, not sure what year this is but an 01 should have the "circuit breaker" between solenoid relay and starter motor shown in the diagram. If the solenoid isn't clicking, the white/black or orange wires to it are not right, check which one, orange should be permanently live with ignition on, white/black neg when start button is pressed, check which is wrong and trace back to the fault. Note the start button and brake "lock out" go via the CDI for no apparent reason.

 

Thank you. I’ll try and trace it out when I get a day off. I HATE electrical.

 

So- I have power to red from battery constant. No power to any of the other three with star pushed or not

 

So I’m hoping this is the culprit. The Orange was not attached to ignition switch

 

White/black should be negative (earthed) when start button pressed, orange comes straight from ignition switch so is always pos with this switch in on position, if it isn't, check the switch. If the red to the switch isn't pos all the time, check that red at both sides of fuse.

 

Ok - I HATE electrical. I found a broken ground/ fixed it. Switched out on/off switch. Push start and it fires right up. Buuuuutttt.... starter keeps turning. Finally get it to shut off and then nothing. Back to no click in relay. Has power from org wire this time. Crazy thing is I am getting little bit of power from whi/blk wire with no button pushed. Put old relay back in and have power to red/white when start button pushed and “click” in relay but no starter movement. Used your diagram and red white goes to circuit breaker then to starter. The “button” on circuit breaker isn’t popped and there is power coming in and out of it -out so now we are stuck again.

 

I test starter circuits with a high wattage test lamp. There is a difference between you getting volts round a circuit, and getting power. Check that the test lamp burns bright with it between an earth on engine and that red/white wire when the starter button is pressed. If it does, your starter is a bit unreliable, I find a lot of LT80 starters are. If it doesn't, try the lamp with earth side on battery neg, if it then lights, the earth between engine and frame is bad. If it still doesn't light, check the red at solenoid with the test lamp..