ZR650-CSi
6.50-inch (165 mm) 2-Way Component System
o w n e r ’ s m a n u a l
Thank you for choosing a JL Audio Evolution ZR Component System
for your automotive sound system. With proper installation, your
new speakers will deliver years of listening pleasure.
We strongly recommend that you have your new Evolution speakers
installed by your authorized JL Audio dealer. The installation
professionals employed by your dealer have the necessary tools
and experience to disassemble your interior panels, install your
new speakers and reassemble your vehicle properly. If you prefer to
perform your own installation, please read this instruction manual
completely before beginning the process.
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ZR650-CSi SPECiFiCATiONS:
Included Components and Parts:
Woofers: Mineral-filled polypropylene cone body,
1-inch (25mm) voice coil, low-profile/ symmetrical-
roll spider, butyl rubber surround
Tweeters: 1-inch (25 mm) aluminum dome
tweeter with soft rubber suspension, neodymium
magnet, ferrofluid cooled and damped, variable
mounting system
Crossover Networks: 2-way network with 1st order
low-pass and 2nd order high-pass circuit, premium
polypropylene film capacitors, air-core inductors and
non-inductive Mills™ resistors, 5-position adjustable
tweeter output level, 4-position midrange presence
control, Polyswitch tweeter protection
• Two ZR650-CWi 6.50-inch (160 mm) Woofers
• Two ZR100-CT 1-inch (25 mm) Tweeters
• Two ZR650/570-CSpxo Crossover Networks
• Two Compact Flush-Mount Tweeter Fixtures
• Two Enhanced Flush-Mount Tweeter Fixtures
• Two Surface-Mount Tweeter Fixtures
• Two Metal Woofer Grilles with ABS Grille Trays
• Two Self-Adhesive ZR Nameplates for Grilles
• Butyl Adhesive Putty for Woofer Grilles
• Twelve #8 x 1.25 inch (30 mm) Sheet Metal Screws
• Four #6 x 1-inch (25 mm) Sheet Metal Screws
• Two 1.18-inch (30 mm) Machine Screws
• Two Metal Spring Clips for Tweeter Fixtures
• Eight Mounting Clips for Woofer Mounting
• Two 6.4 mm Female Crimpable Connectors
• Two 4.7 mm Female Crimpable Connectors
• Four 2.8 mm Male Crimpable Connectors
• Twelve Crimpable Spade Connectors
Continuous Power Handling: 85 Watts (RMS Method)
Peak Music Power: 255 Watts
Recommended Power Range: 25-175 Watts (RMS)
Frequency Response: 48 Hz - 25 KHz ( 3 dB)
Efficiency @ 1W/1m: 89.5 dB
Nominal Impedance: 4 ohms
A l l s p e c i f i c a t i o n s a r e s u b j e c t t o c h a n g e w i t h o u t n o t i c e .
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JL AUDIO ZR650-CSi
3
GETTiNG STARTED:
WiRiNG DiAGRAMS - STANDARD AND
Bi-AMP / Bi-WiRE METHODS:
The input to the crossover networks can be set
up in one of the following two ways:
• Turn off the audio system. It is also advisable
to disconnect the negative (–) terminal of your
vehicle’s battery whenever performing
installation work.
• Before cutting, drilling or inserting any screw, check
clearances on both sides of the planned mounting
surface.Also check for any potential obstacles, such
as window tracks and motors, wiring harnesses, etc.
Check both sides of the vehicle, many vehicles are
not symmetrical!
Standard: This wiring configuration is used when
you wish to drive each crossover with a single
amplifier channel or pair of wires. In this mode, you
will only use the input connections marked “INL+”
and “INL–”on the crossover circuit board (“INH+”
and “INH–” are not used). Your crossovers are pre-
set in this mode at the factory. This mode is selected
by placing the pair of jumper bars shown in Diagram
A to the lower position marked "STD”. Tweeter
(“T+” and “T–”) and woofer output connections
(“W+” and “W–”)are made as shown in Diagram A.
• Always wear protective eyewear.
CROSSOVER NETWORK iNSTALLATiON:
The crossover networks supplied with your ZR
System should be installed in a dry location inside
your vehicle. DO NOT INSTALL THEM INSIDE OF
A DOOR! Doors often get wet on the inside, which
can damage your crossover networks and could
potentially damage your entire sound system. The
crossovers can be screwed into a solid surface via
two holes located under the protective cover of the
case. To access these holes, simply squeeze the sides
of the cover while gently pulling the cover away from
the base. Make sure that your mounting location will
not cause damage to wiring, fuel lines, brake lines or
any other vital component of your vehicle. Once you
have screwed the case in and made your connections,
snap the protective cover back into place.
Bi-Wire (Bi-Amp): This position is selected by
placing the input mode selection jumper bars in the
upper position as shown in Diagram B. In this mode,
the inputs to the woofer’s low-pass filter and the
tweeter’s high-pass filter are electrically isolated.This
permits connection of different amplifier channels to
the woofer and tweeter sections (bi-amp), or separate
wire pairs for each section from a single amplifier
channel (bi-wire). In this mode, you will use the Input
connections marked “INL+” and “INL–” to drive the
low-pass woofer section of the crossover and “INH+”
and “INH–” to drive the high-pass tweeter section of
the crossover.Tweeter (“T+” and “T–”) and woofer
output connections (“W+” and “W–”)are made as
shown in Diagram B.
WARNiNG
! !
! !
It is absolutely vital that your component system is
Please note that the use of additional active
filtering for the woofer low-pass or tweeter high-
pass is not necessary or recommended in this
mode. The crossover network has been engineered
to shape the system response... additional filters
may degrade performance.
connectedasshowninthismanual. Failuretoconnect
the system as shown may result in damage to your
speakers which is NOT covered under warranty.
Do not substitute different crossover networks into
your ZR System. Do not use crossover networks
intended for different ZR models.
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JL AUDIO ZR650-CSi
4
Diagram A: Standard Wiring Diagram
Amplifier
Output
Diagram B: Bi-Wire (Bi-Amp) Wiring Diagram
Woofer
Amplifier
Output
Tweeter
Amplifier
Output
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JL AUDIO ZR650-CSi
5
CROSSOVER NETWORK ADjuSTMENT
The ZR crossover networks have been designed
to allow tonal adjustments to the upper midrange
response and tweeter level. These adjustments
make it possible to fine-tune your system to suit
your listening preferences and to compensate for
various speaker mounting applications.
ADjuSTABLE TWEETER LEVEL:
ZR crossover networks also provide five levels
of tweeter adjustability designed to compensate for
different mounting locations, vehicle interiors and
personal taste. These levels are selectable via a set of
pins located under the clear cover of each crossover
case. We recommend that you begin listening in the
“REF” (Reference) position. To find the optimum
tonal balance in your installation, experiment with
alternate tweeter level settings by moving the jumper
connector. It is safe to switch jumpers while the
system is playing.
ADjuSTABLE MiDRANGE PRESENCE:
Your ZR crossover networks provide a unique
midrange presence control, located under the
clear cover. The midrange presence is selectable
via a set of pins and allows for four settings. These
settings affect the amplitude of the upper midrange
response of the ZR component woofer. We
recommend that you begin your listening with the
factory setting (3) and adjust up or down as needed
to compensate for mounting location, orientation or
personal taste.
TWEETER PROTECTiON:
The ZR crossover networks are equipped with
an advanced electronic tweeter protection circuit
designed to minimize the possibility of tweeter failure.
This electronic device monitors current going to the
tweeter and will disconnect the tweeter from the
signal when it senses overload. Should this occur
while listening to the audio system, simply reduce the
volume for a few seconds and the protection circuit
will reset itself automatically.
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6
JL AUDIO ZR650-CSi
SPEAKER PLACEMENT
CONSiDERATiONS:
You can always experiment with tweeter
placement before committing to a final mounting
location. Simply connect the rest of the system
and allow plenty of wire length for the tweeters.
Using Velcro® or similar material, attach the
tweeters in different locations until you find the
one where they perform best.
Woofers will usually be placed into factory
speaker locations. If you have some woofer
mounting flexibility, keep the following in mind:
Lower mounting locations, such as the lower
front corner of a door or a kick-panel provide
the greatest path length distances for the sound
emitted by the woofer. For this reason, they are
generally more desirable than higher mounting
locations. Higher mounting locations often result
in extreme near-side soundstage bias which
compromises the stereo listening experience.
A component system gives you the ability to place
the woofer and tweeter separately in your vehicle
interior. This can be good or bad, depending on how
it’s done. As a general rule, the tweeters should be
placed relatively close to the woofers for best tonal
balance and most coherent imaging (the closer, the
better). Any separation greater than 8 inches (20 cm)
is likely to result in degraded sound quality.
Avoid placing tweeters where they will be blocked
by objects in the interior of the car (including seated
occupants). When selecting a mounting location,
look at both sides of the car to make sure that this
location is clear on both sides.
Less Desirable Speaker Placement
More Desirable Speaker Placement
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JL AUDIO ZR650-CSi
7
WARNiNG
Custom Location: Run speaker wire to the
desired mounting locations. If you are running
wires into a door, use existing factory wiring boots
whenever possible. If you are drilling new holes,
file their edges and install rubber grommets into
each hole. Wires should then be covered with a
protective, flexible PVC sleeve and then run through
the door jamb. Make sure that the wires will clear
door hinges and other structures in the door. If you
are unsure about any part of this process, please
contact your JL Audio dealer for installation help.
Select an even surface. Tightening a speaker onto
an uneven surface can damage it. Carefully measure
and mark the “mounting hole diameter” outline in
the selected location using the dimensions listed on
page 2. Before drilling or cutting on your interior
panels, use a utility knife to cut any fabric, vinyl or
leather from hole locations. These materials can
easily be snagged by a drill or a saw, causing damage
to the panel and possible bodily injury. Drill a pilot
hole in the center of the proposed speaker mounting
hole. Then, using a saber saw with an appropriate
blade, make the circular cut out for the speaker. File
any rough edges.
After cutting the hole, check to see that the
speaker frame fits into its mounting hole cleanly.
Do not force the frame into a hole that is too small.
Once the speaker is in place, use the holes on the
speaker’s mounting flange to mark the panel where
the four mounting screws will be positioned, as
shown in Diagram D. Remove the speaker and
drill 1/8-inch (3 mm) holes at each mark. Insert the
mounting clips with the flat side towards the speaker.
Connect the speaker wires, observing correct
polarity, and secure the speaker and grille tray to the
panel by evenly tightening by hand the provided #8
x 1.25 inch (16 mm) mounting screws. Make sure the
woofer is secured so that air does not leak around
the mounting flange. Air leaks will cause a severe
degradation in sound quality. Seal any air leaks with
an automotive-grade sealant material.
! !
! !
Double check the clearance for both
speakers before proceeding. Many cars are
different from one side to the other!
WOOFER iNSTALLATiON:
The woofers should be installed in one of the
following ways depending on location:
Factory Location: If you will be using the factory
speaker wires, it may be necessary to change
the terminations. This may be accomplished by
using an adaptor plug or simply by cutting the
factory connector off and using the supplied crimp
connectors to terminate the speaker wires. The large
connector is for the positive ( ) terminal and the
+
small connector is for the negative (–) terminal of
each woofer. Keep in mind that the woofer wires
must be connected to the woofer outputs of the
crossovers supplied with your system as shown
in the diagram on page 5. If you prefer to run new
wires, refer to the “Custom Location” installation
section for details. Whichever method you choose,
observe correct polarity in your connections. If you
are unsure about any of these issues, contact your JL
Audio dealer for installation assistance.
Your new speakers have been designed to install,
without modifications, into most vehicles that accept
a 6.5-inch (160 mm) speaker. Most factory 6.5-inch
speakers use four mounting screws which will line up
with the mounting holes on your woofers.
It is absolutely vital that the speaker frame fits
into the mounting hole cleanly. This must be checked
prior to tightening the screws. Do not force the
frame into a hole that is too small. Do not tighten
the speaker onto an uneven surface. This will
damage your speakers. The speaker should also fit
so that air does not leak around the mounting flange.
Air leaks will cause a severe degradation in sound
quality. Seal any air leaks with an automotive-grade
sealant material.
Break off small pieces of the supplied butyl
Use the supplied mounting clips unless the factory
holes already feature threaded inserts.
Hand-tighten the screws evenly.
adhesive putty and place them on the inside of each
grille tray. This adhesive will hold the grille mesh insert
in place firmly and prevent rattling. Then insert the
grille mesh insert into the grille tray, squeezing gently
around its edge until it seats firmly into the tray.
Finally, attach the self-adhesive ZR logo badge to
the grille mesh insert.
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JL AUDIO ZR650-CSi
8
Diagram C: Factory Location Woofer Installation
Diagram D: Custom Location Woofer Installation
WARNiNG
! !
! !
Hand-tighten the screws evenly in a criss-
cross pattern to avoid bending the speaker
frame or stripping the mounting clips.
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JL AUDIO ZR650-CSi
9
TWEETER iNSTALLATiON:
TWEETER FiXTuRE iNSTALLATiON:
The dome tweeters supplied with your
ZR650-CSi system have been designed for
maximum mounting versatility. There are two
primary methods by which the tweeters can be
mounted in your vehicle:
First, run speaker wires from the tweeter output
of the crossover (see diagrams on page 5) to the
desired tweeter mounting locations, observing
the same precautions as mentioned in the woofer
installation section. Terminate the wires with the
supplied 2.8 mm male crimpable connectors.
Flush-Mount: Two different styles of flush-mount
fixtures are provided: a compact, simple design and
an enhanced design. Both are installed using the
same method (shown in Diagram E), but require
different size mounting cutouts. Refer to page 2 for
cutout dimensions.
Flush-mounting yields a custom-installed
appearance, but will require at least 3/4-inch (19
mm) of clearance behind the mounting surface of
the tweeter. Install as shown in Diagram E, using
the spring clips and 1-inch machine screws (it may
be necessary in some limited depth applications to
cut down the length of the machine screw, or use
a shorter screw (not supplied). Hand-tighten the
machine screw until the fixture is secure.
Surface-Mount: In this application, you will not
need to cut large holes in your vehicle’s panels for
the tweeters. You will only need to drill a hole for
the wires and two smaller holes for the mounting
screws. This application is useful when mounting the
tweeters to a panel that has insufficient clearance
behind it for the tweeter’s magnet structure.
Using the fixture as a template, mark the screw
hole locations and a location in the center of the
fixture for the wire hole. Remove the fixture and
drill pilot holes for the screws and a 1/8-inch (3
mm) for the wires. Use the supplied #6 x 5/8-inch
sheet metal screws to secure the fixture as shown in
Diagram F (hand-tighten). Run the tweeter's wires
through the hole and insert the tweeter until it
snaps into place.
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10
JL AUDIO ZR650-CSi
Diagram E: Flush-Mount Tweeter Installation
Diagram F: Surface-Mount Tweeter Installation
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JL AUDIO ZR650-CSi
11
jL AuDiO LiMiTED WARRANTy (uSA)
Automotive Speaker Systems
JL Audio warrants these speakers (and crossover networks, where applicable) to be free of defects in materials
and workmanship for a period of one (1) year.
This warranty is not transferrable and applies only to the original purchaser from an authorized JL Audio dealer.
Should service be necessary under this warranty for any reason due to manufacturing defect or malfunction,
JL Audio will, at its discretion, repair or replace the defective product with new or remanufactured product at
no charge.
Damage caused by the following is not covered under warranty: accident, misuse, abuse, product modification or
neglect, failure to follow installation instructions, unauthorized repair attempts, misrepresentations by the seller. This
warranty does not cover incidental or consequential damages and does not cover the cost of removing or reinstalling
the unit(s). Cosmetic damage due to accident or normal wear and tear is not covered under warranty.
Any applicable implied warranties are limited in duration to the period of the express warranty as provided
herein beginning with the date of the original purchase at retail, and no warranties, whether express or implied,
shall apply to this product thereafter. Some states do not allow limitations on implied warranties, therefore these
exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state.
if you need service on your jL AuDiO product:
All warranty returns should be sent to JL Audio freight prepaid through an authorized
JL Audio dealer and must be accompanied by proof of purchase (a copy of the original sales receipt.) Direct
returns from consumers or non-authorized dealers will be refused unless specifically authorized by JL Audio with
a valid return authorization number. Warranty expiration on products returned without proof of purchase will be
determined from the manufacturing date code. Coverage may be invalidated as this date is previous to purchase
date. Return only defective components. If one speaker fails in a system, return only that speaker component,
not the entire system. Non-defective items received will be returned freight-collect. Customer is responsible for
shipping charges and insurance in sending the product to JL Audio. Freight damage on returns is not covered
under warranty.
For Service information in the u.S.A. please call:
JL Audio customer service: (954)443-1100
during normal business hours (Eastern Time)
jL Audio, inc
10369 North Commerce Pkwy.
Miramar, FL 33025
international Warranties:
Products purchased outside the United States of America are covered only
by that country’s distributor and not by JL Audio, Inc.
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ZR650-CSi-02082008
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