April 2013
© 2013 Yamaha Motor Corporation, U.S.A. All rights reserved.
Troubleshooting DC-CDI
Ignition Systems
A Direct Current-Capacitor Discharge Ignition
(DC-CDI) system uses a control unit, an ignition
coil, and a pick up coil. The DC-CDI system re-
quires a constant DC voltage supply to the CDI
unit. Normally, this comes from the unit’s battery,
although a capacitor can also be used. The DC
voltage is multiplied inside the CDI control unit
until several hundred volts are stored in the control
unit’s capacitors. That high voltage is then
discharged to the ignition coil when the timed
pulse is received from the
pickup coil. The voltage
that is sent to the igni-
tion coil is stepped up and
delivered to the spark plug
via the ignition coil lead
and cap.
Review the September 2012 issue of
The Service Limit to understand how to
recognize a DC-CDI system.
DC CDI systems are common on many smaller Yamaha
products that have a battery, such as TT-R and many air-
cooled ATV models.
1. The first step in troubleshooting any ignition
system problem is to confirm that the spark-
plug is receiving secondary voltage from the
ignition coil. An inline spark tester will confirm
if the ignition coil is producing secondary
voltage, but you will need a peak voltage test
to make sure that the secondary voltage is
consistent and at an acceptable level.
Secondary voltage should range between 3
and 10 kilovolts (KV) depending on a unit’s
cranking speeds.
2. If secondary voltage is not present, the
system’s engine stop switch system should
be tested next. It can be bypassed quickly for
testing purposes. In most units, the stop
switch will ground the ignition circuit inside
the CDI unit. To temporary bypass this
CDI ignition systems were not used until the late
1960s. What advantages did they offer over earlier
ignition system types?
Look it up!
 type of switch, do it as close to the CDI
connector as possible. Simply disconnect-
ing the wire will open the stop circuit. Once

the engine stop switches have been by-

passed, confirm if secondary voltage is
present. If secondary voltage is still not
present, test the CDI control unit DC voltage
supply and ground.

This diagram, taken from a 2005 R6, shows the power for the DC-CDI ignition
originating with the unit’s battery, #5, routed though the main fuse, #6, the key
switch, #1, and then the ignition fuse, #10. The Red/White wire supplies power
for the DC-CDI control unit.

In this diagram from a Yamaha WaveRunner, the Engine stop switch or the
Engine shut-off switch will connect the White wire, ignition kill, to the Black
wire, ground. This will cause the ignition system to stop firing the spark plugs.
3. DC voltage is typically supplied from the unit’s
battery and is routed through a fuse and
multiple switches to the CDI control unit. With
the CDI control unit connector disconnected,
test for battery voltage at the connector with
all switches in the ON or Run position. If
battery voltage is present, install the
connector to the CDI control unit. Now
inspect the CDI control unit ground wire. If
you verify that voltage supply and ground
circuits are normal, move on to test the voltage is correct at the CDI connector, confirm
pickup coil.
Supplying voltage and ground with jumper wires to the CDI control unit is a
quick and easy test. In many cases, this can quickly eliminate the testing of
several switches.
4. To test the pickup coil, connect a peak-read-
ing voltmeter to the pickup coil leads as
close to the CDI unit as possible At cranking
speeds, the pickup coil should produce 3~7
peak volts. If the pickup coil does not produce
the correct peak voltage at the CDI connector,
do this test at the pickup coil’s connector to
verify that the pickup coil has failed, not the
harness. If the CDI is receiving correct
peak voltage from the pickup coil, test the CDI
peak voltage output to the ignition coil.
5. To test the CDI peak voltage output, connect a
peak-reading meter’s positive lead to the CDI’s
output wire to the ignition coil. Connect the
meter’s negative lead to ground and crank the
engine. At cranking speeds, the CDI should
produce 100~300 peak volts. If there is no output
from the CDI, but no other failure has been found,
the CDI unit may have failed. If the CDI peak
that voltage is traveling through the wire harness
to the ignition coil by doing the same test at the
ignition coil terminal. If the CDI is producing peak
voltage, make sure that the ignition coil ground
is correct. If the correct voltage is getting to the
coil, but it still does not result in secondary spark,
then replace the coil.