Bike won't start shop told me starter clutch or woodruff key bad how do you remove the magneto to check these also the big gear behind magneto i was told is not suppose to spin freely and it does guy at suzuki said woodruff key bad thank for any help

1. check the woodruff key on the flywheel for play, 2. check the magneto with a meter to see if it is bad. 3. Check the magnet strength in the flywheel. 4.check the gap between the fly wheel and the magneto, The gap should be 010.

Deborah, I know very little of the Big Dog Bikes Electrics and not a lot of info out there for the Big Dog, just wanting to help hopefully. Below I will post links different from Gregg's, hoping that they will also help in your bikes dilemma. Check the attached links,instruction and guides, Good luck
"I hope this helped you out, if so let me know by pressing the helpful button. Check out some of my other posts if you need more tips and info."
Where are the fuses
2003 big dog chopper wiring diagram Google Search
Big Dog Chopper Wiring Diagram
2003 big dog chopper wiring diagram Google Search

Check the clutch, neutral and side stand safety interlocks.
Double check that the bike is in neutral, and the clutch is pulled in when trying to start the bike.
If the bike is in gear with the side stand down, the bike cuts off all ignition.
If the clutch isn't pulled in, the starter won't engage.
Check all these safety interlock switches, and make sure you are in neutral with the clutch in when trying to start the bike.

It will not be a bent shift fork. If the clutch lever feels the same pulling the lever in and out as it did before the problem came up then chances are the clutch is okay. Does the lever at the gearbox move properly when the hand lever is moving in and out? Is the clutch cable hanging up on something? I think you are going to find either a broken woodruff key on the gear at the right end of the crankshaft or clutch plates hanging up on the clutch hub. The broken key would prevent power from going to the ring gear on the outer clutch hub. The clutch plates can wear grooves into the clutch inner and or outer hubs. Too deep a groove and the plates can be unable to be compressed by the clutch springs. The result is no power being transmitted through the clutch. Another possibility is a broken shift shaft arm or arm spring. The right engine side cover will need to be removed so you can then do a visual inspection of the crankshaft gear, clutch hub and shift shaft lever. If I knew the year and model and engine size of your Yamaha bike I could offer more exact diagrams. The one below are generic. Go to www.babbittsonline.com and you can see an exploded view of your specific engine. Please rate my answer.

Considering the year of the bike, I wouldn't be afraid to tackle the job, The only way to learn about it is to get your hands dirty, the dealer will only charge you about $1500, They don't make a move for any less. My buddy just took his in for spring service, because it wouldn't start, It cost him $1200 for the minor clean up and tune up. I told him I would have done it for $1150, Check it out.

The starter setup on those Viragoes are not that bad to do. The only thing I don't like about it is the the pinion gear. The pinion gear is also a clutch. When they get old they can either jam or slip. It sounds like the starter is damaged. Check starting system before installing the new starter. You want to make sure there isn't a short. Replace the little clutch setup too I believe it is sold seperately.

Sounds like the starter clutch is slipping and or beginning to fail. You should take it back and have them inspect the starter clutch for scoring or damage.

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/

which seems to have solved the problem I had with the bike jumping out of 5th gear. Now on the not-so-good side. I now seem to have very high pressure in the crankcase enough to spray oil out of the channel that links the generator (rotor) area with the gearbox and coats the rotor and stator with oil. Its as if the oil isn't being picked up properly or maybe if the oil runs through one of the gearbox shafts - do I have to align the oil feed hole in this with something? This was the one thing that I wasn't certain about when I rebuilt the gearbox.... would this cause the problem? I can't find any crankcase breathers that could be blocked so I assume the bottom end vents up the channel for the timing chain, and then out the top camshaft cover and the thick black pipe on the top (which is clear). ,Either you have excess blowby or a passage somewhere is blocked. Leak down test first, then its back to removing covers until you find whats blocked,,,