CDI 197-0001 Installation And Troubleshooting Manual

CDI P/N: 197-0001 Yamaha Voltage Regulator
Replaces P/N: 6R3-81960-00-00 and 6R3-81960-10-00
WARNINGS:
 This product is designed for installation by a professional marine mechanic. CDI cannot be held liable for
injury or damage resulting from improper installation, abuse, neglect or misuse of this product.
DO NOT USE A MAINTAINENCE FREE, AGM OR DRY CELL BATTERY WITH THIS TYPE

REGULATOR/RECTIFIER!!!
NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING AS THIS MAY BURN OUT THE

REGULATOR/RECTIFIER. If the boat is equipped with a battery switch, make sure that it is a make before
break type.
1. Disconnect the negative battery cable.
2. Disconnect and remove the old regulator/rectifier.
3. Install the new regulator/rectifier, using the original mounting bolts.
4. Connect the Black wire to a clean engine ground.
5. Connect the stator's 3 wire connector to the new regulator/rectifier.
6. Connect the Red wire with the Round connector from the harness to the mating connector from the regulator/rectifier.
7. Connect the Red wire with the bullet connector to the mating connector going to the fuse if present. If there is no connection for this
wire, use a cable tie to tie it out of the way so it does not short out.
8. Reconnect the negative battery cable.
BATTERY IS NOT BEING CHARGED:
1. Clean all Battery cables, engine and battery connections, both on the engine and on the battery.
2. Install a clamp on ammeter capable of reading at least 30 amperes on the Red battery cable connected to the starter solenoid.
Start the engine and see if the ammeter is showing a charge going into the battery. If so, swap out the battery for a known good
one. If the engine now shows a charge going into the battery, the old battery is defective.
3. Check the resistance between the stator's Green wires as follows:
Read From Read To
Green 1 Green 2
Green 1 Green 3
Green 2 Green 3
4. Disconnect all connections to the Regulator/Rectifier. Then, using a Multimeter set to diode scale, check the Diodes between the
Regulator/Rectifier's Green wires and the Red Wire as follows:
Red Meter Lead Connection
Green 1
Green 2
Green 3
Red Lead from Regulator/Rectifier
Red Lead from Regulator/Rectifier
Red Lead from Regulator/Rectifier
5. Check the DVA voltage on stator's Green wires as follows:
Read From Read To
Green 1 Green 2
Green 1 Green 3
Green 2 Green 3
*Connected to the Regulator/Rectifier. If the voltage is too high, the Regulator/Rectifier may be defective. If the voltage is too low,
the stator is likely defective.
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Rev D  10/4/2018
Installation and Troubleshooting Guide
NOTE: This installation is to be completed by an Authorized Dealer or Professional Service
Technician. For questions regarding installation or warranty, call CDI Tech Support
at 866-423-4832. Do not return to the Dealer or Distributor where the part was purchased.
Contact CDI Electronics Directly for Return Materiel Authorization.
TROUBLESHOOTING
Disconnected
0.27 to 0.43 Ω
0.27 to 0.43 Ω
0.27 to 0.43 Ω
Black Meter Lead Connection
Red Lead from Regulator/Rectifier 0.4 to 0.6
Red Lead from Regulator/Rectifier 0.4 to 0.6
Red Lead from Regulator/Rectifier 0.4 to 0.6
Green 1
Green 2
Green 3
Disconnected Connected
7V (at cranking) 7V (at cranking)*
7V (at cranking) 7V (at cranking)*
7V (at cranking) 7V (at cranking)*
CDI Electronics, LLC  353 James Record Road SW  Huntsville, AL 35824 USA
www.cdielectronics.com
INSTALLATION
Reading
Open or No Reading
Open or No Reading
Open or No Reading
At 1500 RPM
13 V*
13 V*
13 V*
 Tech Support: 1-866-423-4832  Order Parts: 1-800-467-3371
Page - 1 of 2
At 3500 RPM
11 V*
11 V*
11 V*
QF-358