Iv a problem with my 91 suzuki dr 650 rs,last sept i replaced new starter clutch havent drove it too much execpt weekends cos i work away,but last too drove it every day bike going perfect til this morning engine wont turn when i press strart button sounds exactly like last time when starter clutch went,engine wont turn just makes a noise like a drill i dont understand what has gone wrong with it.please help

Hi,
Looks like a bendix gear drive problem.

Open the starter cover clutch and check the bendix gear, it should push itself when you tried to turn the big gear at the bottom, if it don't move that means it is stuck.
Dip it in kerosene for a day to let the internal mechanism loosen up. If it still stuck, you have to buy a new one.
Bendix gear fail when it run out of lubrication or the roller ball inside gave up.

Hope FixYa solved that problem.

No, it is definately different.
I own a '90 DR650RS model and have the Service Manual from Suzuki. This covers years and models 1990 to 1996.
From the outset, the electric start was added in 1991.
Thus numerous changes are evident with starter relays, clutch relay, duplicated wires to the twin coils and a totally new CDI unit or Black Box!
There is also variants within each year, with differing variations for USA, Canada, Europe, Germany, Australia and Switzerland.
Yearly changes were (are) made right throughout the DR's history. From 1990 to 1992 the position of CDI moved and extra sensors were added for clutch and sidestand in lieu of neutral light. Magneto source coils were also beefed up as was the necessary change to the Rectifier/Regulator to handle the extra required for the starter motor.
I have just experienced some electrical issues and was dismayed to find my stock wiring does not exactly correlate with the specified diagram in the service manual, this is common as I have restored over 30 motorcycles and correctly matching diagrams has been very rare.
I can scan the specific diagram and repost here if you can be specific with year, model and country. IE: the DR650R differs from my DR650RS as does the DR650RSE or RSEU etc.
Cheers!

Fork oil #10 is 570ml amount or 129mm level for each leg.
Cheers!

http://dr650.zenseeker.net/Suspension.htm
This site has a lot of relevent info and many links...I own same model and will be doing similar in the near future. Although I shall be looking at ebay or wreckers for a good s/hand one. Cheers.

is the clutch sliping?...or can you adjust the leaver so its fully out??....if its sliping..you will need new clutch plates.......if it needs adjust..try it...

Sounds like the starter motor clutch is worn or damaged and should be replaced.
Go to the link below and scroll down and click on STARTER CLUTCH. An exploded view diagram and part list is given. All sections of the bike are covered. The starter clutch is not a serviceable item and is replaced when faulty.
Your Yamaha dealer should freely verify the noise if your on good terms with them.
Cheers!
http://www.cmsnl.com/suzuki-dr650-1993-rsep_model13240/partslist/

Sounds like your starter solenoid is not engaging. Try tapping it with a dead blow hammer or a hammer and block of wood (gently! Not to hard!) If it bumps over that is your problem. Also check all connections to solenoid and starter.

The whirring noise you are hearing is your starter motor but your bendix gear is not engaging.

Hope this helps!
Rob

http://www.cmsnl.com/suzuki-dr650-se-usa_model15962/partslist/

Exploded views of the offending parts are here in each segment of the bike. See: Starter clutch, Starter motor, Crankcase, Crank balancer, Magneto.
There are several things turning as a result of the crank. Balancers and idlers all hide in there.
Cheers.

It is not a big job if you know what to do and you have a rotor puller. But you may likely cause big $ damage if you don't.
The "starter clutch" is on the end of the starter motor and when activated turns an idler cog, which then turns the clutch starter set. This clutch starter set is behind the magneto rotor (flywheel) and should not be the problem. To remove the rotor you will require an appropriate size rotor puller available from most larger bike accessories stores for under $20, or the Suzuki Special Tool for 10x the price!
Your problem most likely lies with the starter clutch pack itself and is a parts replacement item.
The link below will provide by exploded view, diagrams of the parts you need to check, at least you can have an idea when you talk to your parts dealer. Cheers.
http://www.cmsnl.com/suzuki-dr650-se-usa_model15962/partslist/

You can drive without filter for a while but you run the risk of getting junk in the carbs that can cause problems later.