Popping when source is switched or muted HUH????

chad, maybe try removing one piece of equipment at a time until you no longer have the problem (go back and start with the last thing you changed, and work backwards). Might help you to isolate the equipment causing it. Maybe there is an alternative method of hooking up the components?
It almost sounds like the processor/premap is dialed up too high and the signal is being amplified by the active crossover.
Just a guess.

I had the problem slightly with my AR-9 towers, now those were 87db efficient, now the Innersounds are 96db so it is all amplified now, I am sending off Rotel for repair. thanks for the help, also I posted pics. take care

I had the same issues with a BAT preamp. Bad output capacitor...not sure if this is what's happending to you. same symptoms.