Kawasaki Jet Ski Lanyard Stop Button

thingiverse

Did you but a vintage jet ski only to learn that it had no ability to kill the engine if you were to fall off. I did. Luckily you and your 3D printer can fix this slight oversight. This is a replacement for the OEM stop button found on some Kawasaki jet skis that adds the use of a lanyard. I have been using this button for three years and it has been extremely reliable. I'm not sure what they were thinking in those early years, but I could not imagine hitting the water knowing my ski would just keep going when I inevitably fall off.I have only used this on a 300SX, but it should work on other skis that use the same part (maybe the X2).What you will need:Stop button bodyStop button topM6 x 25mm screw (widest head possible pan head preferred)M6 nut (10mm wide)Small springThere is a bit of assembly required with this part. You will need an M6 screw to act as the plunger. It will need to be modified to work best. A screw with a large pan head will be your best option. The OD of the screw can be sanded down to fit within the barrel of the button body. You can also grind the face of the bolt flat. A bench grinder will make quick work of this, but chucking it up in a drill and using sandpaper would work as well. If you were to us a hex bolt for this, you will end up removing the flats making it difficult to install. Once that is done, you are ready for the spring. The spring must be stiff enough to press down the stop button reliability. You probably shouldn't use the spring out of a pen or something like that. I was easily able to find a suitable spring at the hardware store. The exact length is not critical but it will affect how much force is applied to the button. I just did a bit of trial and error. The nut is the last part. A simple hex nut will work, but the file is sized for a 10 mm wide. You may need to make some alterations based on your part. AdjustmentWhen you assemble the button, you will need to adjust how far down the plunger sits. Screw in the cap with the nut to raise the plunger. You want the plunger to be just high enough that it is not pressing on the stop button when the lanyard is attached, but not so high that it does not reliably kill the engine. You may need to see if the engine will run or check spark to know if things are in the right place. Once you are confident with the placement you may want to trim bolt if it is sticking past the cap. A dab of thread locker in the nut should be able to lock in the plunger's position. I have not had to readjust the plunger after three years of use.