Marantz 1040 Stereo Integrated Amplifier Restoration

Unit: Stereo Integrated Amplifier

Manufacturer: Marantz

Model: 1040

SN: 1634

Today I'm showcasing a Marantz 1040 stereo integrated amplifier that came in for restoration. This model was manufactured from 1974 to 1978. It produces 20 watts per channel into 8 ohms with no more than 0.3% total harmonic distortion. The optional walnut veneer cabinet for this model is WC-10. The retail price in 1975 was $199.95 (Ref. Marantz Dealer Price List).

Marantz 1040 is a service-friendly amplifier because of very good access to each PCB.

Power Supply Board (P800)

The power supply unit provides +35V DC (pin J807) to the phono amplifier and tone amplifier boards.

 

Four electrolytic capacitors (C803, C804, C805, and C806) installed on this board were replaced with low impedance and high-reliability Nichicon UPM e-caps. The dried glue under each capacitor was carefully removed. The original e-caps were tested with an Atlas ESR70 capacitance meter and the results are below.

Test results on original capacitors removed from the power supply board:

C803: rated capacitance – 330uF, measured – 335uF, ESR – 0.01Ω, deviation: +2%

C804: rated capacitance – 220uF, measured – 251uF, ESR – 0.02Ω, deviation: +14%

C805: rated capacitance – 100uF, measured – 122uF, ESR – 0.05Ω, deviation: +22%

C806: rated capacitance – 220uF, measured – 272uF, ESR – 0.01Ω, deviation: +24%

Power supply board - before and after

Tone Amplifier Board (PE01)

The tone amplifier board has six low leakage capacitors (CE03, CE04, CE07, CE08, CE09, CE10) installed in the signal path, two bi-polar e-caps (CE11, CE12), and three aluminum electrolytic capacitors (CE05, CE06, CE13). The original low leakage e-caps with a rated capacitance of 4.7uF were replaced with modern low leakage Nichicon UKL caps. The other two low leakage e-caps (CE07 and CE08) were replaced with high-quality film polyester WIMA caps. The original bi-polar caps (CE11 and CE12) were replaced with modern bi-polar Nichicon UES caps. And, the remaining aluminum e-caps were replaced with low impedance Nichicon UPW/UPM caps.

Test results on original capacitors removed from the tone amplifier board:

CE03: rated capacitance – 4.7uF, measured – 4.7uF, ESR – 1.39Ω, deviation: +0%

CE04: rated capacitance – 4.7uF, measured – 4.9uF, ESR – 1.26Ω, deviation: +4%

CE05: rated capacitance – 10uF, measured – 11uF, ESR – 0.57Ω, deviation: +10%

CE06: rated capacitance – 10uF, measured – 11uF, ESR – 0.61Ω, deviation: +10%

CE07: rated capacitance – 1uF, measured – 0.8uF, ESR – 3.4Ω, deviation: -20%

CE08: rated capacitance – 1uF, measured – 0.8uF, ESR – 3.6Ω, deviation: -20%

CE09: rated capacitance – 4.7uF, measured – 4.7uF, ESR – 1.31Ω, deviation: +0%

CE10: rated capacitance – 4.7uF, measured – 4.7uF, ESR – 1.54Ω, deviation: +0%

CE11: rated capacitance – 4.7uF, measured – 4.6uF, ESR – 1.39Ω, deviation: -2%

CE12: rated capacitance – 4.7uF, measured – 4.5uF, ESR – 1.4Ω, deviation: -4%

CE13: rated capacitance – 100uF, measured – 114uF, ESR – 0.05Ω, deviation: +14%

Tone amplifier board - before and after

Phono Amplifier Board (P400)

The phono amplifier board has four low leakage capacitors (C401, C402, C413, C414) installed in the signal path, and four aluminum electrolytic capacitors (C409, C410, C415, C416). The original low leakage e-caps (C401 and C402) with a rated capacitance of 4.7uF were replaced with modern low leakage Nichicon UKL caps. The other two low leakage e-caps (C413 and C414) were replaced with film polyester WIMA caps. The remaining aluminum e-caps were replaced with low impedance Nichicon UPW caps. Note that the capacitance deviation of the two original e-caps (C409 and C410) is almost 70% of the nominal value.

Test results on original capacitors removed from the phono amplifier board:

C401: rated capacitance – 4.7uF, measured – 4.5uF, ESR – 2.1Ω, deviation: -4%

C402: rated capacitance – 4.7uF, measured – 4.6uF, ESR – 1.5Ω, deviation: -2%

C409: rated capacitance – 100uF, measured – 167uF, ESR – 0.19Ω, deviation: +67%

C410: rated capacitance – 100uF, measured – 168uF, ESR –0.14 Ω, deviation: +68%

C413: rated capacitance – 1uF, measured – 0.8uF, ESR – 2.8Ω, deviation: -20%

C414: rated capacitance – 1uF, measured – 0.8uF, ESR – 2.6Ω, deviation: -20%

C415: rated capacitance – 100uF, measured – 118uF, ESR – 0.23Ω, deviation: +18%

C416: rated capacitance – 47uF, measured – 53uF, ESR – 0.26Ω, deviation: +13%

Phone amplifier board - before and after

Main Amplifier Board (P700)

The main amplifier board in Marantz 1040 is the most difficult board for servicing. This model does not have transistor sockets for power transistors. The leads of the four power transistors are directly soldered to wires. This design makes it difficult to disconnect the board from the heat sink since all transistors have to be de-soldered from the wires. This board can still be serviced with all wires connected, but in this case, the power transistors cannot be tested for current gain.

The main amplifier board has four low leakage e-caps (C701, C702, C705, C706) and five aluminum electrolytic capacitors (C709, C710, C711, C712, and C717). The original low leakage e-caps were replaced with modern low leakage Nichicon UKL caps. The remaining aluminum e-caps were replaced with low impedance Nichicon UPW caps. Note that the original e-cap C705 has only ~50% of the rated capacity.

Test results on original capacitors removed from the main amplifier board:

C701: rated capacitance – 3.3uF, measured – 3.1uF, ESR – 3.4Ω, deviation: -6%

C702: rated capacitance – 3.3uF, measured – 2.9uF, ESR – 3.9Ω, deviation: -12%

C705: rated capacitance – 47uF, measured – 25uF, ESR – 1.18Ω, deviation: -47%

C706: rated capacitance – 47uF, measured – 44uF, ESR – 0.14Ω, deviation: -6%

C709: rated capacitance – 100uF, measured – 121uF, ESR – 0.18Ω, deviation: +21%

C710: rated capacitance – 100uF, measured – 119uF, ESR – 0.34Ω, deviation: +19%

C711: rated capacitance – 47uF, measured – 52uF, ESR – 0.16Ω, deviation: +11%

C712: rated capacitance – 47uF, measured – 51uF, ESR – 0.64Ω, deviation: +9%

C717: rated capacitance – 10uF, measured – 11uF, ESR – 2.6Ω, deviation: +10%

The first stage of the main amplifier circuit is a differential pair amplifier consisting of two amplifying transistors with a common emitter: H701/H703 (left channel) and H702/H704 (right channel). The original PNP transistors installed in these positions are 2SA722. These transistors are not on my list of notorious transistors prone to failure. However, the owner of this amplifier complained about some distortion from the right channel and I decided to test the original 2SA722s to make sure they are well matched by current gain. So, I di-soldered all four transistors and tested them with Atlas DCA55 semiconductor analyzer. The pair of transistors from the left channel was very well matched (the current gain of H701 and H703 is 234 and 235, respectively). But the pair of original 2SA722s from the right channel had a mismatch of ~29% (the current gain of H702 and H704 is 273 and 353, respectively). Transistors installed in the differential pair amplifier are supposed to be gain matched as much as possible and a 29% mismatch is a lot for proper operation. So, I replaced the original 2SA722 transistors in both channels with new Fairchild KSA992 transistors. Before installation, each pair of KSA992 transistors was carefully matched by current gain and base-emitter voltage. 

Test results on original 2SA722 transistors

H701 (left channel): hfe - 234, Vbe - 0.750V 

H703 (left channel): hfe - 235, Vbe - 0.752V

H702 (right channel): hfe - 273, Vbe - 0.788V 

H704 (right channel): hfe - 353, Vbe - 0.789V

Test results on new KSA992 transistors

H701 (left channel): hfe - 403, Vbe - 0.760V 

H703 (left channel): hfe - 403, Vbe - 0.759V

H702 (right channel): hfe - 405, Vbe - 0.759V 

H704 (right channel): hfe - 406, Vbe - 0.761V

Main amplifier board - before and after

Power Transistors

The original power transistors were removed, cleaned, and tested with an Atlas DCA55 semiconductor analyzer. The test showed that the left channel NPN transistor (H002, 2SC1667) has a shunt between the base and the emitter. I measured the resistance between the base and emitter and it was very low at ~8.3kΩ. The remaining three transistors passed the test. 

NPN power transistor 2SC1667 from the left channel - shunt between the base and emitter

I don't have any new 2SC1667 transistors in stock and decided to replace all original power transistors with new ON Semiconductor transistors. Keep in mind that the NPN transistor 2SC1667 is a complement to the PNP transistor 2SA837. So, you can not install another NPN power transistor with similar parameters instead of 2SC1667. Well, you can but it is not the right thing to do. I replaced the original 2SC1667/2SA837 transistors in each channel with new MJ21194G/MJ21193G transistors. The new transistors are specifically designed for high-power audio output, have excellent gain linearity, and complement each other. The new Mica pads and fresh thermal compound were applied between each power transistor and heat sink. The fresh thermal compound was also applied to the thermal tracking diodes H005 and H006.

Original and new ON Semiconductor power transistors

Pilot Lamp

The old pilot lamp was replaced with a new incandescent lamp. The yellowish old vellum paper in front of the pilot lamp was replaced as well.

Old and new pilot lamp

DC offset and Bias Adjustments

The Bias is measured across two emitter resistors. The voltage drop across resistors R751 and R753 should be adjusted to ~20mV DC with the trimming resistor R763 (the DC voltmeter is connected between pins J709 and J711). This is a bias on the left channel. And on the right channel, the voltage drop across resistors R752 and R754 should be adjusted to ~20mV DC with the trimming resistor R764 (the DC voltmeter is connected between pins J720 and J721).

The DC offset is measured between pin J707 and ground on the left channel, and between pin J718 and ground on the right channel. It should be adjusted as close to zero volts as possible with the trimming resistors R761 and R762, respectively.

Bias on the left and right channels after restoration

DC offset on the left and right channels after restoration

Output Power Test

The final output power test was performed at the end of my restoration. The amplifier was loaded with a low inductance 8Ω/100W dummy resistor for each channel. The oscilloscope was connected across the speaker terminals and a sine-wave signal of 1kHz was applied to the AUX jacks. The output sine-wave signal was perfectly symmetrical on both channels with no clipping up to 13.48 VRMS (left channel) and 13.41 VRMS (right channel). It corresponds to the output power of 22.7W on the left channel and 22.5W on the right channel.

Output power test

As usual, all the knobs and the face plate were gently cleaned in warm water with dish soap. All controls have been cleaned with DeoxIT 5% contact cleaner and lubricated with DeoxIT FaderLube 5% spray.

The final result can be seen in the photos below. The amplifier looks like new again. The sound is excellent, with deep bass and clear highs. Please watch a short demo video at the end of this post. Thank you for reading.

Marantz 1040 - after restoration

Demo video after repair & restoration

Sherwood S-7210 Receiver Restoration

Unit: AM/FM Stereo Receiver

Manufacturer: Sherwood

Model: S-7210

SN: 511645

Today I'm showcasing a Sherwood S-7210 AM/FM stereo receiver that came in for restoration. This model was introduced in 1974 and produces 26 watts per channel into 8 ohms with less than 0.6% total harmonic distortion. The damping factor is 30. The list price in 1974 was $299.95 (Ref. High Fidelity Magazine, September 1974, page 27).

The Sherwood S-7210 is a service-friendly receiver. Each board can be easily accessed for servicing.

Selector & Pre-Amp Board

The selector & pre-amp board has two solid tantalum capacitors (C501a, C501b) and twelve aluminum electrolytic capacitors (C503a, C503b, C504a, C504b, C505a, C505b, C506a, C506b, C512, C513, C514, C515). The solid tantalum capacitors are installed in the input signal path and I replaced them with modern low leakage Nichicon UKL e-caps. The ordinary aluminum e-caps C505a and C505b installed in the output signal path were replaced with high-quality film polyester WIMA caps. And, the remaining aluminum capacitors were replaced with low impedance Nichicon UPW caps.

The original e-caps were tested with an Atlas ESR70 capacitance meter and the results are below. Five of the fourteen capacitors are outside of factory spec.

Test results on original capacitors removed from the selector & pre-amp board:

C501a: rated capacitance – 4.7uF, measured – 5.3uF, ESR – 1.58Ω, deviation: +13%

C501b: rated capacitance – 4.7uF, measured – 4.9uF, ESR – 1.92Ω, deviation: +4%

C503a: rated capacitance – 22uF, measured – 28uF, ESR – 1.12Ω, deviation: +27%

C503b: rated capacitance – 22uF, measured – 28uF, ESR – 1.04Ω, deviation: +27%

C504a: rated capacitance – 33uF, measured – 36uF, ESR – 0.55Ω, deviation: +9%

C504b: rated capacitance – 33uF, measured – 34uF, ESR – 0.66Ω, deviation: +3%

C505a: rated capacitance – 1uF, measured – 1.3uF, ESR – 2.9Ω, deviation: +30%

C505b: rated capacitance – 1uF, measured – 1.2uF, ESR – 2.9Ω, deviation: +20%

C506a: rated capacitance – 10uF, measured – 11uF, ESR – 1.35Ω, deviation: +10%

C506b: rated capacitance – 10uF, measured – 11uF, ESR – 1.42Ω, deviation: +10%

C512: rated capacitance – 33uF, measured – 41uF, ESR – 0.72Ω, deviation: +24%

C513: rated capacitance – 33uF, measured – 41uF, ESR – 0.81Ω, deviation: +24%

C514: rated capacitance – 10uF, measured – 11uF, ESR – 1.39Ω, deviation: +10%

C515: rated capacitance – 10uF, measured – 11uF, ESR – 1.42Ω, deviation: +10%

Two NPN transistors (TR502a & TR502b) installed on this board are Toshiba 2SC1000. This transistor is known to get noisy over time. I replaced the original 2SC1000 transistors with modern low-noise Fairchild KSC1845s. The new transistor has the same pinout as the original one.

Selector & pre-amp board - before and after

Main Amp & Power Supply Board

The power supply, tone control amplifier, and main amplifier are all located on a single PCB.

The power supply circuit provides -11.3V DC to the tuner board, and balanced power to the main power amplifier from the bridge rectifier and two filter capacitors. The circuit has two aluminum electrolytic capacitors (C807, C808) and two axial filter capacitors (C805, C806). The two aluminum e-caps were replaced with low impedance and high-reliability Nichicon UPW caps. Both axial 4700uF/35V filter capacitors were replaced with new 4700uF/40V Vishay 021ASM series caps. I usually don't replace large filter capacitors in vintage gears unless their ESR is high or the measured capacitance exceeds the nominal one by more than +/- 10%. But it makes sense in this particular case since the ESR of each original filter cap is relatively high and the measured capacitance is very low in comparison to the nominal value.

Test results on original capacitors removed from the power supply circuit:

C805: rated capacitance – 4700uF, measured – 2362uF, ESR – 0.13Ω, deviation: -50%

C806: rated capacitance – 4700uF, measured – 2214uF, ESR – 0.14Ω, deviation: -53%

C807: rated capacitance – 33uF, measured – 32uF, ESR – 3.8Ω, deviation: -3%

C808: rated capacitance – 33uF, measured – 33uF, ESR – 3.8Ω, deviation: 0%

The tone control circuit has six aluminum electrolytic capacitors (C901a, C901b, C902a, C902b, C906a, C906b) installed in the signal path, and two filtering aluminum e-caps (C908 and C909). Four ordinary aluminum e-caps with a nominal capacitance of 1uF were replaced with film polyester WIMA caps to improve the signal-to-noise ratio. The other two e-caps with a nominal capacitance of 4.7uF were replaced with modern low leakage Nichicon UKL caps. And the remaining filtering aluminum capacitors were replaced with low impedance Nichicon UPM caps.

Note, that one of the original capacitors installed in this circuit completely failed the test (C906b, open circuit).

Test results on original capacitors removed from the tone control circuit:

C901a: rated capacitance – 1uF, measured – 1.3uF, ESR – 1.66Ω, deviation: +30%

C901b: rated capacitance – 1uF, measured – 1.2uF, ESR – 2.4Ω, deviation: +20%

C902a: rated capacitance – 1uF, measured – 1.2uF, ESR – 2.2Ω, deviation: +20%

C902b: rated capacitance – 1uF, measured – 1.2uF, ESR – 2.1Ω, deviation: +20%

C906a: rated capacitance – 4.7uF, measured – 5.1uF, ESR – 1.8Ω, deviation: +9%

C906b: rated capacitance – 4.7uF, measured – open circuit

C908: rated capacitance – 220uF, measured – 298uF, ESR – 0.14Ω, deviation: +36%

C909: rated capacitance – 470uF, measured – 508uF, ESR – 0.08Ω, deviation: +8%

The main amplifier circuit has nine aluminum electrolytic capacitors: C601a, C601b, C604a, C604b, C605a, C605b, C606a, C606b, and C611. Two of them (C601a and C601b) are installed in the input signal path. I replaced them with film polyester WIMA caps to improve the signal-to-noise ratio. The other e-caps were replaced with low impedance Nichicon UPW/UHE caps.

Note, that two out of nine original capacitors installed in this circuit completely failed the test (C605b and C611, open circuit). Also, the measured capacitance of e-cap C604a is very close to the nominal but its ESR is very high.

Test results on original capacitors removed from the main amplifier circuit:

C601a: rated capacitance – 1uF, measured – 1.2uF, ESR – 1.74Ω, deviation: %

C601b: rated capacitance – 1uF, measured – 1.2uF, ESR – 2.4Ω, deviation: %

C604a: rated capacitance – 33uF, measured – 34uF, ESR – 8.3Ω, deviation: %

C604b: rated capacitance – 33uF, measured – 33uF, ESR – 3.5Ω, deviation: %

C605a: rated capacitance – 33uF, measured – 33uF, ESR – 2.8Ω, deviation: %

C605b: rated capacitance – 33uF, measured – open circuit

C606a: rated capacitance – 100uF, measured – 87uF, ESR – 0.19Ω, deviation: %

C606b: rated capacitance – 100uF, measured – 86uF, ESR – 0.22Ω, deviation: %

C611: rated capacitance – 4.7uF, measured – open circuit

The first stage of the main amplifier circuit is a differential pair amplifier consisting of two amplifying transistors with a common emitter: TR601a/TR602a (left channel) and TR601b/TR602b (right channel). The original PNP transistors installed in these positions are 2SA640. These transistors are not on my list of notorious transistors prone to failure. However, before I started servicing this receiver I measured the DC offset across the speaker terminals and noticed a relatively high (but still safe) voltage in the right channel. The measured DC offset in the left channel was ~14mV (perfectly good) but in the right channel, the measured voltage was ~55mV. This voltage should be as close to zero volts as possible within +/- 50mV. Usually, if this voltage is relatively high (but still within a safe range) the problem might be with mismatched transistors installed in the differential amplifier. So, I unsoldered the original 2SA640 transistors and tested each pair with Atlas DCA55 semiconductor analyzer. The measured current gain of two transistors TR601a and TR602a (left channel) was 542 and 491, respectively. It gives an ~10% difference between them. Not too bad, but remember that transistors installed in the differential amplifier are supposed to be closely matched to operate properly in the circuit. Then, I measured the current gain of two transistors TR601b and TR602b installed in the right channel. The measured gain was 563 and 449, respectively. It gives ~25% difference between them which is rather substantial. 

I replaced all original 2SA640's with modern Fairchild KSA992 transistors. Before installation, each pair of KSA992 transistors was carefully matched by current gain and base-emitter voltage. After the new transistors were installed the DC offset on each channel became close to 0V within +/- 10mV.

I also noticed that the body of two resistors (R803 and R915) is damaged. The R803 is installed in the power supply circuit, and the R915 is in the tone control circuit. I didn't see any signs of overheating though. So, I am not sure what caused their damage. Despite the body being damaged the measured resistance of R803 and R915 is still very close to the nominal resistance. It makes sense to replace these two resistors as a part of preventive maintenance. The original R803 was replaced with a new Vishay power metal film resistor. And the R915 was replaced with a new KOA Speer metal film resistor.

The body of two original resistors R803 and R915 is damaged

New resistors R803 and R915 are installed

Main amp & power supply board - before and after

Dial and Meter Lamps

The dial and meter lamps in this unit have been already replaced with warm white LED lamps by the owner.

New dial and meter lamps - warm white LEDs

Output Power Test

The final output power test was performed at the end of my restoration. The receiver was loaded with a low inductance 8Ω/100W dummy resistor for each channel. The oscilloscope was connected across the speaker terminals and a sine-wave signal of 1kHz was applied to the AUX jacks. The output sine-wave signal was perfectly symmetrical on both channels with no clipping up to 16.16 VRMS (left channel) and 15.88 VRMS (right channel). It corresponds to the output power of 32.6W on the left channel and 31.5W on the right channel.

Output power test

As usual, all the knobs and the front panel were gently cleaned in warm water with dish soap. All controls have been cleaned with DeoxIT 5% contact cleaner and lubricated with DeoxIT FaderLube 5% spray.

The final result can be seen in the photos below. Please watch a short demo video at the end of this post. Thank you for reading.

Sherwood S-7210 - after restoration

Demo video after repair & restoration

Yamaha CR-1000 Receiver Restoration

Unit: FM Stereo Receiver

Manufacturer: Yamaha

Model: CR-1000

SN: 6394

Today I'm showcasing a Yamaha CR-1000 natural sound FM stereo receiver that came in for restoration. This model was introduced in 1974 and produces 70 watts per channel into 8 ohms with less than 0.1% total harmonic distortion. The damping factor is 70.

As far as I know, the Yamaha CR-1000 had a limited distribution and was initially sold only in Japan as a high-end model for 180,000¥. The US list price was $799.95 (Ref. High Fidelity Magazine, June 1974, page 50). It is a forerunner of the famous CR-1020, CR-2020, and CR3020 AM/FM stereo receivers introduced to the market a few years later. The CR-1000 was a milestone. As the Yamaha sales brochure states the CR-1000 is a combination of an outstanding FM tuner and an extremely low-distortion, high-power, versatile amplifier, both of which could stand by themselves as independent Hi-Fi components. The unit features the world's first application of negative feedback to the FM tuner's multiplex switching circuit, resulting in very low harmonic distortion and intermodulation distortion. Because the FM tuner uses an elaborate 5-gang tuning capacitor, as well as a triple tuning circuit with dual-gated MOSFET's, the quality of FM reception is at the highest level presently possible for a tuner of any cost.

The direct-coupled OCL power amplifier itself allows negative feedback to be applied evenly from DC to far above the audio spectrum while reducing distortion and expanding the power bandwidth to 5 - 50,000Hz with a total harmonic distortion of 0.5%. It also extends the damping factor and output characteristics through the very low frequencies, contributing excellent transient response capabilities in the low-frequency range.

That being said, the Yamaha CR-1000 is not a service-friendly receiver, and you'll soon see why.

Main Amplifier Board (NA06599)

The main amplifier board has two bi-polar capacitors (C601, C603) and one aluminum e-cap (C609). The bi-polar capacitor C601 installed in the input signal path was replaced with a high-quality film polyester WIMA cap. Another bi-polar capacitor C603 was replaced with a new bi-polar Nichicon UES cap. The remaining aluminum e-cap C609 was replaced with a low impedance Nichicon UPW cap.

Test results on original capacitors removed from the main board:

Left channel:

C601: rated capacitance – 2.2uF, measured – 2.1uF, ESR – 1.48Ω, deviation: -5%

C603: rated capacitance – 47uF, measured – 52uF, ESR – 0.08Ω, deviation: +11%

C609: rated capacitance – 220uF, measured – 241uF, ESR – 0.12Ω, deviation: +10%

Right channel:

C601: rated capacitance – 2.2uF, measured – 2.1uF, ESR – 2.7Ω, deviation: -5%

C603: rated capacitance – 47uF, measured – 53uF, ESR – 0.07Ω, deviation: +13%

C609: rated capacitance – 220uF, measured – 243uF, ESR – 0.11Ω, deviation: +11%

All original trimming resistors (VR601, VR602, VR603) were replaced with new Bourns potentiometers.

Main amplifier board (left and right channel) - before and after

Power Supply Board (NA06598)

The power supply board in almost any vintage gear is fairly easy to access and service. But this is not the case with Yamaha CR-1000. This is where the troubles begin. You need to remove the tuner unit to access the power supply board. No, I am not kidding. This "smart" engineering solution is designed to worsen the life of a technician. In fact, the tuner unit must be removed to access any of the printed circuit boards, except for the two main amplifier boards. Did I tell you that I'm not a big fan of Yamaha vintage gears? Anyway, let's get back to work.

Remove the four red-topped 3x8S bind tapping screws, two large slot screws, and the red-topped screws. Then remove the tuner unit. That's what it says in the service manual. Will the tuner unit be completely disconnected from the rest of the chassis to make the servicing easy? No! It will be still connected to the other boards. And you should be extremely careful not to pull too hard on the leads when removing the tuner unit. Otherwise, some leads or wires can be broken. So, think twice if you want to service this receiver yourself.

Yamaha CR-1000 - the tuner unit is removed (but still connected to other boards!)

The power supply board has sixteen aluminum electrolytic capacitors (C802, C803, C804, C805, C806, C808, C810, C811, C812, C813, C814, C815, C817, C818, C822, C823)  and two bi-polar e-caps (C819, C820). All aluminum e-caps (except the e-cap C808) were replaced with low impedance Nichicon UPW/UPM/UHE caps. The aluminum e-cap C808 and bi-polar e-cap C820 were replaced with high-quality film polyester WIMA caps. And the remaining bi-polar e-cap C820 was replaced with a new bi-polar Nichicon UEP cap.

Test results on original capacitors removed from the power supply board:

C802: rated capacitance – 220uF, measured – 233uF, ESR – 0.04Ω, deviation: +6%

C803: rated capacitance – 220uF, measured – 246uF, ESR – 0.04Ω, deviation: +12%

C804: rated capacitance – 220uF, measured – 228uF, ESR – 0.02Ω, deviation: +4%

C805: rated capacitance – 220uF, measured – 241uF, ESR – 0.01Ω, deviation: +10%

C806: rated capacitance – 10uF, measured – 13uF, ESR – 0.72Ω, deviation: +30%

C808: rated capacitance – 1uF, measured – 1.3uF, ESR – 2.5Ω, deviation: +30%

C810: rated capacitance – 470uF, measured – 604uF, ESR – 0.09Ω, deviation: +29%

C811: rated capacitance – 220uF, measured – 277uF, ESR – 0.14Ω, deviation: +26%

C812: rated capacitance – 220uF, measured – 264uF, ESR – 0.14Ω, deviation: +20%

C813: rated capacitance – 470uF, measured – 596uF, ESR – 0.08Ω, deviation: +27%

C814: rated capacitance – 220uF, measured – 274uF, ESR – 0.13Ω, deviation: +25%

C815: rated capacitance – 33uF, measured – 33uF, ESR – 0.68Ω, deviation: 0%

C817: rated capacitance – 47uF, measured – 44uF, ESR – 0.12Ω, deviation: -6%

C818: rated capacitance – 47uF, measured – 52uF, ESR – 0.11Ω, deviation: +11%

C819: rated capacitance – 100uF, measured – 114uF, ESR – 0.21Ω, deviation: +14%

C820: rated capacitance – 1uF, measured – 1uF, ESR – 0.61Ω, deviation: 0%

C822: rated capacitance – 10uF, measured – 12uF, ESR – 2.1Ω, deviation: +20%

C823: rated capacitance – 4.7uF, measured – 6.1uF, ESR – 0.55Ω, deviation: +30%

The original speaker protection relay (HC2-P-DC12V) was replaced with a new Omron MY2-02-DC12 relay. The original relay was still functional but I replaced it anyway. Recently, I started to replace the protection relay in all vintage gears even if they are still functional. It is now a part of preventive maintenance. Even the protection relay still works fine, the relay contacts usually toasted, and no one knows how long it will last. The toasted contacts are poor conductors and often result in intermittent distortion in either the left or right channel.

The four NPN transistors (TR806, TR813, TR815, and TR816) installed on this board are 2SC458 transistors that are prone to failure. I replaced them with new Fairchild KSC1845 transistors. Watch the pinout on replacement transistors. The original transistor is BCE and the new one is ECB.

Power supply board - before and after

Filter Amplifier Board (NA06592)

Reminder: first of all, remove the tuner unit. Again, this is not a joke.

The filter amplifier board has six solid tantalum capacitors (C601, C602, C603, C604, C619, C620) installed in the signal path, and six aluminum electrolytic capacitors (C605, C606, C609, C610, C617, C618). Two tantalum capacitors C603 and C604 were replaced with high-quality film polyester WIMA caps. The other four tantalum caps were replaced with modern low leakage Nichicon UKL caps. And the remaining aluminum e-caps were replaced with low impedance Nichicon UPW caps.

Test results on original capacitors removed from the filter amplifier board:

C601: rated capacitance – 2.2uF, measured – 2.2uF, ESR – 0.52Ω, deviation: 0%

C602: rated capacitance – 2.2uF, measured – 2.2uF, ESR – 0.72Ω, deviation: 0%

C603: rated capacitance – 1uF, measured – 1.0uF, ESR – 3.7Ω, deviation: 0%

C604: rated capacitance – 1uF, measured – 1.1uF, ESR – 2.2Ω, deviation: +10%

C605: rated capacitance – 10uF, measured – 13uF, ESR – 1.41Ω, deviation: +30%

C606: rated capacitance – 10uF, measured – 12uF, ESR – 1.61Ω, deviation: +20%

C609: rated capacitance – 10uF, measured – 13uF, ESR – 1.38Ω, deviation: +30%

C610: rated capacitance – 10uF, measured – 12uF, ESR – 1.49Ω, deviation: +20%

C617: rated capacitance – 100uF, measured – 125uF, ESR – 1.44Ω, deviation: +25%

C618: rated capacitance – 100uF, measured – 130uF, ESR – 0.37Ω, deviation: +30%

C619: rated capacitance – 2.2uF, measured – 2.2uF, ESR – 1.26Ω, deviation: 0%

C620: rated capacitance – 2.2uF, measured – 2.1uF, ESR – 1.61Ω, deviation: -5%

Filter amplifier board - before and after

Mic Amplifier Board (NA06591)

First of all, remove the tuner unit.

The Mic amplifier board has three solid tantalum capacitors (C652, C654, C655) installed in the signal path, and three aluminum electrolytic capacitors (C651, C659, C663). I replaced the tantalum capacitors with film polyester WIMA caps. And the remaining aluminum e-caps were replaced with low impedance Nichicon UPW caps.

Test results on original capacitors removed from the mic amplifier board:

C651: rated capacitance – 47uF, measured – 51uF, ESR – 0.32Ω, deviation: +9%

C652: rated capacitance – 1uF, measured – 1.1uF, ESR – 3.4Ω, deviation: +10%

C654: rated capacitance – 1uF, measured – 1.1uF, ESR – 5.6Ω, deviation: +10%

C655: rated capacitance – 1uF, measured – 1.1uF, ESR – 6.5Ω, deviation: +10%

C659: rated capacitance – 100uF, measured – 131uF, ESR – 2.1Ω, deviation: +31%

C663: rated capacitance – 4.7uF, measured – 5.3uF, ESR – 1.58Ω, deviation: +13%

Mic amplifier board - before and after

Tone Control Amplifier (NA06593)

First of all, remove the tuner unit.

The tone control amplifier board has six solid tantalum capacitors (C471, C472, C485, C486, C487, C488) installed in the signal path, and four aluminum electrolytic capacitors (C479, C480, C481, C482). Two tantalum capacitors C471 and C472 were replaced with film polyester WIMA caps. The other four tantalum caps were replaced with modern low leakage Nichicon UKL capacitors. And the remaining aluminum e-caps were replaced with low impedance Nichicon UPW caps.

Test results on original capacitors removed from the tone control amplifier board:

C471: rated capacitance – 1uF, measured – 1.1uF, ESR – 3.8Ω, deviation: +10%

C472: rated capacitance – 1uF, measured – 1.1uF, ESR – 0.9Ω, deviation: +10%

C479: rated capacitance – 100uF, measured – 120uF, ESR – 0.35Ω, deviation:+20 %

C480: rated capacitance – 100uF, measured – 123uF, ESR – 0.34Ω, deviation: +23%

C481: rated capacitance – 10uF, measured – 13uF, ESR – 2.21Ω, deviation: +30%

C482: rated capacitance – 10uF, measured – 13uF, ESR – 1.54Ω, deviation: +30%

C485: rated capacitance – 3.3uF, measured – 3.4uF, ESR – 1.11Ω, deviation: +3%

C486: rated capacitance – 3.3uF, measured – 3.3uF, ESR – 1.57Ω, deviation: 0%

C487: rated capacitance – 33uF, measured – 36uF, ESR – 2.3Ω, deviation: +9%

C488: rated capacitance – 33uF, measured – 34uF, ESR – 0.36Ω, deviation: +3%

Tone control amplifier - before and after

Equalizer Amplifier Board (NA06594)

First of all, remove the tuner unit.

The equalizer amplifier board has eight solid tantalum capacitors (C401, C402, C415, C416, C427, C428, C429, C430) installed in the signal path, and three aluminum electrolytic capacitors (C413, C414, C431). Four tantalum capacitors (C401, C402, C415, C416) were replaced with film polyester WIMA caps. Note, that the original e-cap C402 has a very high ESR value. The other four tantalum caps were replaced with modern low leakage Nichicon UKL capacitors. And the remaining aluminum e-caps were replaced with low impedance Nichicon UPW caps.

Test results on original capacitors removed from the equalizer amplifier board:

C401: rated capacitance – 1uF, measured – 1.0uF, ESR – 5.1Ω, deviation: 0%

C402: rated capacitance – 1uF, measured – 1.0uF, ESR – 14.1Ω, deviation: 0%

C413: rated capacitance – 33uF, measured – 34uF, ESR – 0.76Ω, deviation: +3%

C414: rated capacitance – 33uF, measured – 35uF, ESR – 0.85Ω, deviation: +6%

C415: rated capacitance – 1uF, measured – 1.1uF, ESR – 1.22Ω, deviation: +10%

C416: rated capacitance – 1uF, measured – 1.1uF, ESR – 1.23Ω, deviation: +10%

C427: rated capacitance – 4.7uF, measured – 4.8uF, ESR – 1.16Ω, deviation: +2%

C428: rated capacitance – 4.7uF, measured – 4.8uF, ESR – 0.88Ω, deviation: +2%

C429: rated capacitance – 4.7uF, measured – 4.8uF, ESR – 0.96Ω, deviation: +2%

C430: rated capacitance – 4.7uF, measured – 4.9uF, ESR – 1.38Ω, deviation: +4%

C431: rated capacitance – 47uF, measured – 51uF, ESR – 0.81Ω, deviation: +9%

Equalizer amplifier board - before and after

Power Transistors

The original Sanken's power transistors (2SC1116 x 2, 2SA747 x 2) were removed, cleaned, and tested with Atlas DCA55 semiconductor analyzer. The measured DC current gain on three out of four transistors was in spec. But the NPN transistor (2SC1116) from the right channel has a relatively low gain. I decided to replace all four power transistors with new ON Semiconductor MJ21193G/MJ21194G transistors. The new transistors are specifically designed for high-power audio output and have excellent gain linearity. So, it is a perfect choice as substitution transistors for the original Sanken's power transistors.

Below are the test results on the original and new power transistors. It should be noted that Atlas DCA55 semiconductor analyzer provides the accurate reading for DC current gain only on low power transistors. A high-power transistor requires a much higher collector current and collector-emitter voltage to accurately measure its current gain. However, it is still a very useful device for comparing transistors of a similar type for the purposes of gain matching or fault-finding.

Test results on original power transistors

TR611 (left channel, 2SC1116): gain - 65, Vbe - 0.592V 

TR612 (left channel, 2SA747): gain - 118, Vbe - 0.614V

TR611 (right channel, 2SC1116): gain - 26, Vbe - 0.583V 

TR612 (right channel, 2SA747): gain - 77, Vbe - 0.603V

Test results on new ON Semiconductor power transistors

TR611 (left channel, MJ21194G): gain - 62, Vbe - 0.596V 

TR612 (left channel, MJ21193G): gain - 86, Vbe - 0.605V

TR611 (right channel, MJ21194G): gain - 56, Vbe - 0.599V 

TR612 (right channel, MJ21193G): gain - 85, Vbe - 0.606V

New ON Semiconductor power transistors are installed - left and right channel

Meter Lamps

Two of the three original meter lamps were burned out in this unit. I replaced them with new incandescent lamps. This is perhaps the easiest part while servicing the Yamaha CR-1000. But you must first remove the tuner unit to unsolder the lamp wires from the PCB (sad but true).

Meter lamps - original, removed from the lamp holders

Original and new meter lamps

Meter lamps - new lamps are installed

Dial Pointer Lamp

There is no backlit to the dial scale in CR-1000 but the dial pointer is illuminated (similar to the Yamaha CR-1020). And unlike many other vintage receivers, it's relatively easy to replace the burned pointer bulb on this model. One just needs to unscrew two small screws on the top of the dial pointer unit and the lamp will be released.

Original dial pointer lamp - disassembled from the holder

A new lamp was installed

Filter Capacitors

Two filter capacitors are located under the tuner unit (sorry about that). I tested them with Atlas ESR70 capacitance meter (in-circuit test). Both caps are still within the factory capacitance tolerance and have almost zero ESR. So, I didn't change them. In general, the filter capacitors rarely fail in vintage gears, and I usually don't replace them unless their ESR is high.

In-circuit test on two filter capacitors - both are still in spec

Filter cap #1: rated capacitance – 10000uF, measured – 9365uF, ESR – 0.02Ω, deviation: -6%

Filter cap #2: rated capacitance – 10000uF, measured – 9409uF, ESR – 0.01Ω, deviation: -6%

Main Amplifier Adjustments

Three adjustments should be done to each main amplifier board: (i) primary stage differential amplification circuit current, (ii) mid-point voltage (or DC offset), and (iii) idling current (or Bias). All three steps are clearly described in the service manual.

(i) The DC voltmeter should be connected between terminals TP1 (-) and TP2 (+). The voltage should be adjusted to 15V +/- 0.15V with the trimming resistor VR602.

(ii) The DC voltmeter should be connected between terminals OUT and E. The voltage should be adjusted to 0V +/- 10mV with the trimming resistor VR601.

(iii) The DC voltmeter should be connected between terminals TP3 (+) and TP4 (-). The voltage should be adjusted to 47mV +/- 10mV.

Primary stage differential amplification circuit current on the left and right channels after restoration

Mid-point voltage (or DC offset) on the left and right channels after restoration

Idling current (or Bias) on the left and right channels after restoration

Output Power Test

The final output power test was performed at the end of my restoration. The receiver was loaded with a low inductance 8Ω/100W dummy resistor for each channel. The oscilloscope was connected across the speaker terminals and a sine-wave signal of 1kHz was applied to the AUX jacks. The output sine-wave signal was perfectly symmetrical on both channels with no clipping up to 26.41 VRMS (left channel) and 26.07 VRMS (right channel). It corresponds to the output power of 87.2W on the left channel and 85.0W on the right channel.

Output power test

As usual, all the knobs and the front panel were gently cleaned in warm water with dish soap. All controls have been cleaned with DeoxIT 5% contact cleaner and lubricated with DeoxIT FaderLube 5% spray (I recommend doing it while servicing all boards located under the tuner unit. Otherwise, the tuner unit should be disassembled again to reach most switches and sliders). The wood case was treated with Howard's Restor-A-Finish.

The final result can be seen in the photos below. The receiver looks great, works properly, and sounds awesome. Please watch a short demo video at the end of this post. Thank you for reading.

Yamaha CR-1000 - after restoration

Demo video after repair & restoration