This is quite common with CDI ignition systems, I have had it on Hondas and have never cured it, the engine will spark if turned over on the pull start but only fire once using the electric starter. Because Kawasaki's DC ignition is much simpler than Honda's, it should be an easier fix. Some people recon it is caused by dirt and swarf stuck to the pickup coil in the engine.

 

Checked the pickup coil all clean and adjusted to the magnito still same problem

 

Has any one came to a conclusion on the no spark issue? Mine will not spark when turning over but will spark once after letting off of start button. I have replaced the pickup, stator and cdi box. It still has the same issue. One thing that I tried was removing the pickup from inside the flywheel housing and then reassembling the flywheel housing. I left the pickup wire hooked up. While cranking the engine if I pass a screwdriver over the pickup magnet it will spark every time. This made me think that there was an issue with the flywheel (maybe magnetized?). I ordered a used flywheel from eBay and still have the same issue. I can even pass the tab from the flywheel across the pickup magnet while both are removed from engine and it will spark every time while the engine is cranking. Has anyone heard of flywheel issues? Could I have purchased another bad flywheel?

 

I have always suspected the pickup coil theory to be a bit of a red herring. Why would it spark better when wound (slowly) on the pull start than the electric one. I would guess at a slight weakness in the CDI or a resistance in the wires to it, from earth or ignition switch, but I too have done the checking earth wires, fitting new CDI, fitting new battery, fitting new starter, only to end up with a bike that still only fires up when you take your finger off the button. This was on a Honda 350 though and they have a wire from CDI to the neutral switch that, I have since found, can cause these symptoms.

 

These same spark issues I've had before. The problem is fairly simple.
It's no voltage in the start position. Find 12 volts @ the ign switch. Run a extra wire from the switch to the coil to fire the ign. in start mode.

 

I have exactly the same problem ! Did any of you come up with an answer??