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There must be something else going on . . .

. . .that I cannot understand verbally from your description. If a capacitor is functioning properly there should be no DC voltage on the other side as you expect. There is no music playing when you make the DC measurement right? If there is then this could possibly fool your voltmeter into reading a voltage even though it is not DC.

The only other thing I can think of is that there is unwanted DC coming elsewhere from the player that shares the same trace as the output of the coupling cap. But here's the main thing I will leave you with :

You are correct that it isn't a good idea to have DC voltage floating on the audio output that feeds a pre amp, passive volume control, amplifier, or whatever else next in line. Even if you do have a DC blocking cap in the front of the component next in line, what if you forget about this problem and use the player somewhere else that cannot handle such a DC voltage? (Passive volume controls come to mind.) You will have to deal with that possible damage too. I wish I could just email myself over to take a quick look at it. Maybe some day that will be possible. That would be cool!

If you have honestly verified that the caps are not shorted/damaged and that the outputs of those caps are not connected to anything else ANYWHERE when you measure the DC voltage then I am at a loss.

Anyone else???

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