Hi S2000 enthusiasts! After searching for good instructions on replacing my 2003 S2000's stock speakers, I realized that they were all for AP2 S2000's, which vary in design of the door panels. So, here is my solution to my own dilemma. Hopefully it will shine some light on yours too! Keep in mind, my speakers were 6.5". I had to custom make speaker brackets with my handy 3D printer. If you get smaller speakers, you will likely be able to use the stock speaker "bucket". Also, I prefer component speakers for the quality of sound you get. There are extra parts to install, but it is worth the quality of sound. When looking for car audio, always check out Crutchfield.com for info on fitment and other ideas.
Step 1: Tools/Parts Needed
Please remember that SAFETY is the most important goal when working with potentially dangerous tools and chemicals. Ventilation for chemical usage and proper placement of sharp or hot tools is VERY important! ALWAYS wear eye protection when using a Dremel. Things fly off, discs break into millions of fast flying pieces. You may need various other supplies like electrical tape, paper towels, band-aids, etc.
Step 2: Preparation H
For my install, I put the top down for ease of access and pulled into the garage in case of rain (typical here in FL). Make sure you have a place to put door panels without damaging the panels or the car. I used a towel on top of my hood to protect both. All of these pictures are on the passenger side door. The driver's door is mostly the same except an extra connector is present for the mirrors (I included a pic of that). Remember to take a break if you get frustrated and feel like smashing something. Be careful around sharp edges so as not to bleed on everything.
I installed Polk Audio DB6502 6.5" speakers. They are fairly priced on Amazon.com and have great frequency response. Another plus is they are marine rated. So if you leave your top down or windows open and they get soaked, no biggie!
My head unit was replaced a year or two ago. It is a Kenwood KDC-X599 and it sounds pretty good with these component speakers.
Step 3: Lets Get This Party Started
Start by removing the plastic caps from the interior door handle CAREFULLY. Use a small common (flat head) screwdriver to pry.
Step 4: Remove Screws
Remove the 2 phillips head screws with your screwdriver. A bit and socket type driver will not work because the hole is deep and narrow.
Step 5: Remove Door Latch Handle Cover Plate Screw
Find the screw hiding behind the door handle and remove it.
Step 6: Remove the Plate
Step 7: Remove Plastic Fastener
Step 8: Pop Fasteners Loose on Door Panel
Once the fasteners are all loose, it is just a matter of pulling up slightly on the door panel to get the top part out of the window channel so you can access the wiring.
Step 9: Unplug Connectors
There are only two connectors on the passenger side. The drivers side is the same except there is another connector for the mirrors.
Step 10: Remove the Tweeter From the Door Panel
Step 11: Prepare Stock Tweeter Bracket for Re-use
Depending on the type of speakers you buy and whether or not the tweeter is attached to the woofer, you might not need to replace the tweeter. If you do, you might have to figure out your mounting situation for your bracket.
Step 12: Install New Tweeter
I was lucky that the plastic housing that came with my tweeters had a hole smaller than the screw that held it to the bracket, so i just had to screw it in.
Step 13: Woofer Removal
Be sure to measure the depth from the top of the woofer to the metal on the door to ensure your custom bracket (if needed) will be the same size.
Step 14: Prepare the Woofer Wires
I like to save as much of the stock hardware as possible, so I remove the connectors for hoarding. If you have the Homer Simpson personality, I would recommend cutting the wires off. It is a whole lot of anguish getting these connectors off.
Step 15: Remove Speaker Bucket (if Not Using)
Step 16: 3D Print Custom Brackets (if Necessary)
You can also make one out of MDF. I would have preferred that, but I didn't have it readily available. I think I am going to make a fiberglass bucket for it too. Polk speakers sound much better in an enclosed box, but I'm not sure if this small size will matter enough to hear a difference.
Step 17: Prepare Wires for Woofer
Step 18: Hook Up Woofer
If you are using the stock speaker wire for speakers without a crossover, you will have to either use the stock terminals to go to the speaker or cut/replace them. Or solder them. I prefer not to solder something I might change or access frequently.
Step 19: Prepare Wiring for the Tweeter
If you are using the stock wiring with a tweeter that has no crossover, you will need to cut the stock connector off and terminate it.
Step 20: Prepare the Crossover and Mounting Area
Step 21: Test Your Fancy New Speakers
Step 22: Install Crossover
Step 23: We Are Ready to Put the Door Panel Back On! YAAAAY!
Step 24: Turn It Up and Annoy Your Neighbors!
Hopefully your installation was a breeze and you didn't mind my excessive use of "whilst" (I'm bringing it back). Have fun and enjoy!