JL Audio ZR650-CSi User Manual

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6.50-inch(165 mm)2-WayComponent 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.






























Woofer Physical Dimensions



Frame Outer Diameter (A)



6.50 in. / 165.1 mm


Grille Tray Outer Diameter (B)



6.76 in. / 171.7 mm


Magnet Outer Diameter (C)



3.54 in. / 90.0 mm


Frontal Grille Protrusion (D)



0.98 in. / 24.9 mm


Mounting Hole Diameter (E)



5.56 in. / 141.3 mm


Mounting Depth (F)



2.65 in. / 67.3 mm








































Tweeter Fixture Physical Dimensions









Mounting Fixture Outer Diameter (A)

2.13 in. / 54.0 mm

1.90 in. / 48.3 mm

1.82 in / 46.2 mm

Mounting Fixture Mounting Hole Diameter (B)

1.72 in. / 43.5 mm

1.68 in. / 42.6 mm


Fixture Mounting Depth (C)


0.40 in. /10.3 mm

0.45 in. / 11.5 mm


Tweeter Frontal Protrusion (D)


0.46 in. /11.7 mm

0.39 in. / 9.9 mm

0.85 in. / 21.6 mm






Crossover Network Physical Dimensions

Height (A)

5.86 in. / 148.9 mm

Width (B)

4.17 in. / 105.8 mm

Depth (C)

1.68 in. / 42.8 mm




Included Components and Parts:

Woofers: Mineral-filledpolypropylene cone body,

• Two ZR650-CWi6.50-inch(160 mm) Woofers

1-inch(25mm) voice coil,low-profile/symmetrical-

• Two ZR100-CT1-inch(25 mm) Tweeters

roll spider, butyl rubber surround

• Two ZR650/570-CSpxoCrossover Networks

Tweeters: 1-inch(25 mm) aluminum dome

• Two Compact Flush-MountTweeter Fixtures

tweeter with soft rubber suspension, neodymium

• Two Enhanced Flush-MountTweeter Fixtures

magnet, ferrofluid cooled and damped, variable

• Two Surface-MountTweeter Fixtures

mounting system


• Two Metal Woofer Grilles with ABS Grille Trays

Crossover Networks: 2-waynetwork with 1st order

• Two Self-AdhesiveZR Nameplates for Grilles

low-passand 2nd orderhigh-passcircuit, premium

• Butyl Adhesive Putty for Woofer Grilles

polypropylene film capacitors, air-coreinductors and

• Twelve #8 x 1.25 inch (30 mm) Sheet Metal Screws

non-inductiveMills™ resistors,5-positionadjustable

• Four #6 x 1-inch(25 mm) Sheet Metal Screws

tweeter output level, 4-positionmidrange presence

• Two 1.18-inch(30 mm) Machine Screws

control, Polyswitch tweeter protection

• Two Metal Spring Clips for Tweeter Fixtures



• Eight Mounting Clips for Woofer Mounting

Continuous Power Handling: 85 Watts (RMS Method)

• Two 6.4 mm Female Crimpable Connectors

Peak Music Power: 255 Watts

• Two 4.7 mm Female Crimpable Connectors

Recommended Power Range: 25-175Watts (RMS)

• Four 2.8 mm Male Crimpable Connectors

Frequency Response:

48 Hz - 25 KHz (± 3 dB)

• Twelve Crimpable Spade Connectors

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 .



Getting Started:

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!

Always wear protective eyewear.


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.

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It is absolutely vital that your component system is connected as shown in this manual. Failure to connect 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.

Wiring Diagrams - Standard and Bi-amp /Bi-wiremethods:

The input to the crossover networks can be set up in one of the following two ways:

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–”onthe crossover circuit board (“INH+” and“INH–”are not used). Your crossovers are preset 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–”)aremade as shown in Diagram A.

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’slow-passfilter and the tweeter’shigh-passfilter 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 thelow-passwoofer section of the crossover and “INH+” and“INH–”to drive thehigh-passtweeter section of the crossover.Tweeter (“T+” and“T–”)and woofer output connections (“W+” and“W–”)aremade as shown in Diagram B.

Please note that the use of additional active filtering for the woofer low-passor tweeter highpass is not necessary or recommended in this mode. The crossover network has been engineered to shape the system response... additional filters may degrade performance.



Diagram A: Standard Wiring Diagram



Diagram B: Bi-Wire(Bi-Amp)Wiring Diagram


Amplifier Amplifier

Output Output




























Adjustable Tweeter Level:

The ZR crossover networks have been designed

ZR crossover networks also provide five levels

to allow tonal adjustments to the upper midrange

of tweeter adjustability designed to compensate for

response and tweeter level. These adjustments

different mounting locations, vehicle interiors and

make it possible to fine-tuneyour system to suit

personal taste. These levels are selectable via a set of

your listening preferences and to compensate for

pins located under the clear cover of each crossover

various speaker mounting applications.

case. We recommend that you begin listening in the


“REF” (Reference) position. To find the optimum


tonal balance in your installation, experiment with

Adjustable Midrange Presence:

alternate tweeter level settings by moving the jumper

Your ZR crossover networks provide a unique

connector. It is safe to switch jumpers while the

midrange presence control, located under the

system is playing.

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.



Speaker Placement Considerations:

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

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-panelprovide 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 extremenear-sidesoundstage bias which compromises the stereo listening experience.

More Desirable Speaker Placement











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Double check the clearance for both speakers before proceeding. Many cars are different from one side to the other!


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 factory6.5-inchspeakers 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-gradesealant material.

Use the supplied mounting clips unless the factory holes already feature threaded inserts.

Hand-tightenthe screws evenly.

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-gradesealant material.

Break off small pieces of the supplied butyl 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-adhesiveZR logo badge to the grille mesh insert.



Diagram C: Factory Location Woofer Installation

Diagram D: Custom Location Woofer Installation

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Hand-tightenthe screws evenly in a crisscross pattern to avoid bending the speaker frame or stripping the mounting clips.




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.


The dome tweeters supplied with your ZR650-CSisystem have been designed for maximum mounting versatility. There are two primary methods by which the tweeters can be mounted in your vehicle:

Flush-Mount:Two different styles offlush-mountfixtures 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-mountingyields acustom-installedappearance, but will require at least3/4-inch(19 mm) of clearance behind the mounting surface of the tweeter. Install as shown in Diagram E, using the spring clips and1-inchmachine 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-tightenthe 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 x5/8-inchsheet 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.



Diagram E: Flush-MountTweeter Installation

Diagram F: Surface-MountTweeter Installation



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-authorizeddealers 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-defectiveitems received will be returnedfreight-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)443-1100during 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.