JL Audio Portable Speaker ZR650 CSi User Manual

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.  
 
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 .  
 
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.  
 
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  
 
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.  
 
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  
 
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.  
 
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.  
 
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.  
 
10  
JL AUDIO ZR650-CSi  
Diagram E: Flush-Mount Tweeter Installation  
Diagram F: Surface-Mount Tweeter Installation  
 
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.  
 
ZR650-CSi-02082008  

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