JL Audio XR650-CSi User manual

Thank you for choosing a JL Audio Evolution XR 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. Also, keep in mind
that your warranty coverage extends to 1 year if your system is
installed or approved by your authorized JL Audio dealer. If you
prefer to perform your own installation, please read this instruction
manual completely before beginning the process.
XR650-CSi
6.50-inch (160 mm) 2-Way Component System
owner’s manual

XR650-CSi SPECIFICATIONS:
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 with swivel/
rotation capability.
Crossover Networks: 2-way network with 1st
order low-pass and 2nd order high-pass circuit.
Premium polypropylene film capacitors and air-core
inductors. 5-position adjustable tweeter output
level. 3-position midrange presence control.
Polyswitch tweeter protection.
Continuous Power Handling:
70 Watts (RMS Method)
Frequency Response: 48 Hz - 25 KHz (± 3 dB)
Efficiency @ 1W/1m: 89.5 dB
Nominal Impedance: 4 ohms
Included Components and Parts:
• Two XR650-CW 6.50-inch (160 mm) woofers
• Two XR100-CT 1-inch (25 mm) tweeters
• Two XR650-CSxo 2-Way Crossover networks
• Two Flush-Mount tweeter fixtures with metal
spring clips and optional trim rings
• Two Surface-Mount tweeter fixtures
• Two Metal Woofer Grilles and Grille Trays
• Butyl adhesive putty for woofer grilles
• Twelve #8 x 1 1/4-inch (30 mm)
sheet metal screws
• Four #6 x 5/8-inch (16 mm) sheet metal screws
• Two 1-inch (25 mm) machine screws
• Eight Mounting Clips
• 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
• Four black nylon wire ties
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.
WARNING!
It is absolutely vital that your component
system is connected as shown in the diagrams
below. Failure to connect the system as
shown will result in damage to your speakers
which is NOT covered under warranty.
Do not substitute different crossover networks
into your XR650-CSi System. Only use crossover
networks clearly marked “XR650/570-CSpxo”.
2JL AUDIO XR650-CSi

STANDARD OR BI-WIRE (BI-AMP) INPUT SELECTION:
The input to the crossover networks can be set up two ways:
Standard: Your crossovers are pre-set in this position at the factory.This position is selected by placing the
jumpers in the lower position as shown above. Use this setting to drive the crossovers with a single amplifier
channel or pair of wires. In this mode, you will only use the input connections marked “Main Input” on the
crossover cover (“INL+” and “INL–” on the crossover circuit board.) Follow the white markings labeled
“Standard” on the crossover cover.
Bi-Wire (Bi-Amp): This position is selected by placing the jumpers in the upper position as shown below. In
this mode, the input to the woofer’s low-pass filter and the tweeter’s high-pass filter is electrically isolated.This
way, you can connect different amplifier channels to the woofer and tweeter sections (bi-amp), or you can run
separate wires for each section from the amplifier (bi-wire). In this mode, you will use the Input connections
marked “Tweeter Input” and “Woofer Input” on the crossover cover (“INL+”,“INL–”, “INH+” and “INH-” on
the crossover circuit board). Follow the gold markings labeled “Bi-Wire” on the crossover cover.
Please note that the use of additional active filtering on the amplifiers or outboard active crossovers is not
recommended in this mode for the woofer low-pass or the tweeter high-pass.
JL AUDIO XR650-CSi 3
BI-WIRE
STANDARD
BI-WIRE
STANDARD
HIGH MID
NORMAL
LOW MID
+1.5dB
REF
-1.5dB
-3.0dB
-4.5dB
Twt+ Twt- Wfr- Wfr+ InH- InH+ InL- InL+
JL AUDIO
XR650/
570-CS pxo
JL AUDIO
Polypropylene Capacitor
4.00 µF
Woofer
Amplifier
Output
Tweeter
Amplifier
Output
BI-WIRE
STANDARD
BI-WIRE
STANDARD
HIGH MID
NORMAL
LOW MID
+1.5dB
REF
-1.5dB
-3.0dB
-4.5dB
Twt+ Twt- Wfr- Wfr+ InH- InH+ InL- InL+
JL AUDIO
XR650/
570-CS pxo
JL AUDIO
Polypropylene Capacitor
4.00 µF
Amplifier
Output
A) Standard Input
B) Bi-Wire Input

ADJUSTABLE TWEETER LEVEL:
Your XR Crossover networks 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 at the “REF” (Reference) position. If the
sound seems too bright or aggressive, experiment
with alternate tweeter level settings by moving the
jumper connectors. It is safe to switch jumpers
while the system is playing.
TWEETER PROTECTION:
The XR 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.
+1.5dB
REF
-1.5dB
-3.0dB
-4.5dB
ADJUSTABLE MIDRANGE PRESENCE:
Your XR crossover networks also provide a
unique midrange presence control, located under
the clear cover.The midrange presence is
selectable via a set of pins and allows for three
settings: “High-Mid”, “Normal” and “Low-Mid”.The
settings affect the overall amplitude of the upper
midrange response of the XR component woofer.
We recommend that you begin your listening with
the “Normal” setting and adjust up or down as
needed to compensate for mounting location or
personal taste.
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 More Desirable
HIGH MID
NORMAL
LOW MID
-4.5dB
Twt+ Twt- Wfr- Wfr+ InH- InH
JL AUDIO
XR650/
570-CS pxo
4JL AUDIO XR650-CSi

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 will usually result in
extreme near-side soundstage bias which
compromises the stereo listening experience.
CROSSOVER NETWORK
INSTALLATION:
The crossover networks supplied with your XR
System should be installed in a dry location of 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, snap
the protective cover back into place.
If screwing the crossovers networks in is not
possible, you can also run the supplied nylon wire
ties through the mounting holes to attach the
crossovers to a structure in your car. To do so, take
Less Desirable More Desirable
the covers off, attach the wire ties, and then snap
the covers back into place, lining the wire ties up
with the slots on the sides of the protective cover.
Make sure that you do not attach the crossovers to
a moving part or to any part that may interfere with
pedal operation, gear shift operation, steering, or
airbag deployment.
For wiring instructions, refer to the
diagram on page 3 of this manual.
INSTALLING THE WOOFERS IN
FACTORY LOCATIONS:
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 3.
You may also choose to run new speaker wires...
refer to the custom 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 6.50-inch (160 mm) speaker. Most factory 6.50-
inch speakers use four mounting screws which will
line up with the mounting holes on your woofers.
Multiple sets of mounting holes are available to
accommodate different vehicles’ factory hole
patterns/orientations. 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 no air leaks around
the mounting flange. Air leaks will cause a severe
degradation in sound quality. Seal any air leaks with
silicone, rope caulk or similar sealant material.
JL AUDIO XR650-CSi 5

Install as shown in the diagram here.
Use the supplied mounting clips unless the
factory holes already feature threaded inserts.
Hand-tighten the screws evenly to avoid bending
the speaker frame!
INSTALLING THE WOOFERS IN
CUSTOM LOCATIONS:
Run speaker wire to the desired mounting
location. 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. Then, cover the
wires with a protective PVC sleeve and run them
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.
Double check the clearance for both speakers
before proceeding.
Use the supplied template on the bottom of the
product packaging to mark the desired mounting
location. Mark the center and the outline of the
mounting hole as well as the mounting screw
positions. Before drilling or cutting, 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 four 1/8-inch (3 mm) holes for the
speaker’s mounting screws at the positions you have
marked. Also drill a pilot hole in the center of the
speaker mounting hole at this time. Then, using a
saber saw, hole saw or nibbler, make the circular cut
out for the speaker. File any rough edges. Insert the
mounting clips with the flat side towards the
speaker as shown in the diagram.
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 no air leaks around the mounting flange.
Air leaks will cause a severe degradation in sound
quality. Seal any air leaks with silicone, rope caulk or
similar sealant material.
Connect the speaker wires, observing correct
polarity, and install the speaker and grille tray
as shown.
Hand-tighten the screws evenly to avoid bending
the speaker frame!
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 in place
firmly and prevent rattling. Then insert the metal
grille into the grille tray, squeezing gently around its
edge until it seats firmly into the tray.
6JL AUDIO XR650-CSi

TWEETER INSTALLATION:
The dome tweeters supplied with your
XR650-CSi system have been designed for
maximum mounting versatility. There are two
primary methods by which the tweeters can be
mounted in your vehicle:
1) Flush Mounted, using the supplied flush-mount
cup and hardware.This application will yield a
custom-installed appearance, but will require at least
3/4-inch (19 mm) of clearance behind the mounting
surface of the tweeter.
2) Surface Mounted, using the supplied surface
mount kit and hardware. In this application, you will
not need to cut holes in your vehicle’s panels for
the tweeters.You will only need to drill a hole for
the wires and for the two 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.
Run speaker wires from the tweeter output of
the crossover 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.
Swivel/Rotation Mechanism:
Once the tweeter has been mounted into the
flush mount cup as shown above, it can be swiveled
and rotated by hand to best enhance imaging using
the swivel/rotation mechanism built into the flush
mount system. Experiment with different angles
until you arrive at the best solution. The
swivel/rotation feature will not operate with the
surface mount system.
JL AUDIO XR650-CSi 7
1a 1b 1c
1d 1e 2
Assemble the Flush-Mount Cup Mounting Hole Diameter: 1.75 in. (45 mm) Attach the Tweeter to the Swivel Assembly
Insert the tweeter
and swivel asembly
into the mounted
flush-mount cup,
feeding the wires
through the slots
in the rear of the cup.
Line up the arms of
the swivel assembly
with the slots on the
inside of the flush
mount cup
Tighten
Screw
Vehicle
Panel
Use two thin metal objects as shown to release
the tweeter element from the flush-mount cup.

JL AUDIO LIMITED WARRANTY (USA)
Evolution 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 ninety (90) days from the original date of purchase. The warranty term is
extended to one (1) year if installation is performed or approved by an authorized JL Audio dealer (proof of
installation or approval required on purchase receipt).
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: [phone]
during normal business hours (Eastern Time)
JL Audio, Inc
10369 North Commerce Pkwy.
Miramar, FL 33025
(do not send product for repair to this address)
International Warranties:
Products purchased outside the United States of America are covered only
by that country’s distributor and not by JL Audio, Inc.
Printed in USA JLXR650CSi-02-2003