Interesting
You bring up some good points. I'm running the RP-3's which have crossovers at 2750 and 90 Hz. I'm curious if I set the speakers to small, won't I lose a majority of the low frequencies to the mains? I guess the other thing is that it only happens on one movie, so maybe it's not worth worrying about, it's just that it boggles my mind that just one movie shuts it down. I'll have to look at the mixing of the DVD. I can't remember if I was playing DTS or DD soundtracks, but I thought it was THX mastered, in which case I think there's max levels that can be sent to each channel.
Also, it's my understanding that it might be detrimental to utilize the receiver's crossover directly to the mains. True? Something about running crossover's in series or something.
However, you do bring up a point I'll look at on the speakers themselves, that being the crossover setting on the back, although that still wouldn't affect the fact that the full range amplified signal is still being fed to it. Ugh. I might try the receiver's size setting just to see how it sounds...