Skullcandy Crusher 540 Active Review: The Best Full-Size Workout Headphones?

Explore the Skullcandy Crusher 540 Active—full-size workout headphones with powerful bass and sporty features designed for gym lovers.

A Fresh Take on Full-Size Workout Headphones

Gym rats and fitness buffs who appreciate solid sound quality know well the struggle: the selection of full-size headphones tailored for workouts is painfully sparse. I find myself constantly wondering, why are there so few options? Most guides on the best workout headphones focus on earbuds, leaving full-size fans like me yearning for more. The alternatives often boil down to standard full-size headphones adapted awkwardly for exercise, ending in sweaty, uncomfortable ears.

Enter the Skullcandy Crusher 540 Active—a long-awaited addition to this nearly empty market niche. Right from the jump, this model offers some clever features that place it ahead of its closest rivals. But, as with anything Skullcandy, a few quirky details make me pause and ask: why complicate things?

Designed for the Gym, but Not Without Quirks

You might assume that Skullcandy, the American audio brand synonymous with bass-heavy sound and bold designs, is a natural fit for creating workout headphones. Indeed, their website even sports a whole section dedicated to gym and training headphones. But most options there are just ordinary headphones marketed as “suitable” for workouts. The Crusher 540 Active, however, is different—they’re built specifically with exercise in mind.

The “Crusher” name signals one of the headset’s standout traits: a bass slider that can dial your low-end from normal to earth-shaking. This slider cranks up the bass from “standard” to “my head is vibrating” territory. If you’re the type who thrives on booming beats at the gym, this feature alone is a game-changer.

Longtime Skullcandy fans might notice the Crusher 540 Active strongly resembles the Crusher Evo, with a similar price point in many markets. This sparked some confusion, prompting Skullcandy to clarify on Reddit the key differences between the two.

For starters, the 540 Active comes with removable, washable ear cushions—a blessing for sweaty workouts—and the headband is supposed to offer a snug fit. Sadly, that snugness didn’t translate perfectly for me; during floor exercises, the headphones often slipped off, which could be a dealbreaker depending on your workout style.

Sound Quality: Solid but Not Spectacular

When it comes to sound, the Crusher 540 Active delivers what you pay for: good, but not stellar audio. Yet, its companion app offers one of the best personal sound calibration tests I’ve ever used. It’s simple, intuitive, and surprisingly accurate in tailoring the sound to your ears. That said, with the bass slider maxed out, fine-tuning the audio becomes almost redundant.

While some features impressed me—especially the bass control and sound personalization—the app feels barebones. I was expecting more options, but given some connectivity hiccups I experienced (more on that later), perhaps it’s wise they kept things simple.

So, Should You Buy Them for Workouts?

After several weeks of testing, I’m torn. The Crusher 540 Active worked great for running, upright workouts, and regular listening. But I found myself removing them during floor exercises because of their fit issues. Before pulling the trigger, consider your fitness routine carefully—is your workout mostly standing and moving, or does it involve a lot of lying down?

Skullcandy Crusher 540 Active: Launch Details and Pricing

• Released: Summer 2025
• Price: $210 (approximately $210 USD)
• Few direct competitors in the full-size workout headphone market

The Skullcandy Crusher 540 Active dropped in summer 2025, priced at $210, placing them right alongside the Crusher Evo and slightly less expensive than the Crusher ANC 2, while costing more than the Hesh 540 ANC. This slots them comfortably in the mid-range Skullcandy lineup.

Since the market for dedicated full-size workout headphones is so narrow, there aren’t many direct alternatives to compare within this category.

Key Specs at a Glance

• Drivers: 40 mm
• Active Noise Cancellation: None
• Battery Life: 40 hours
• Weight: 312 grams
• Connectivity: Bluetooth 5.0
• Water Resistance: No official rating

Features That Define the Crusher 540 Active

• Bass slider for extra low-end punch
• Impressive 40-hour battery life
• Personalized sound tuning via app

The star feature here is undoubtedly the bass slider on the left earcup—a nod to the Crusher legacy. This slider lets you govern how bass-heavy your music gets, from modest workout-friendly lows to full-on vibrating-subwoofer levels.

It’s an exhilarating experience to crank the bass on the right track—the kind that makes you feel you’ve walked into a lively London nightclub. Audiophiles might find the bass amplification a bit crude and inconsistent, but for a gym boost, it’s irresistibly fun.

Keep in mind, the headphones lack active noise cancellation, relying instead on the passive noise isolation from their snug ear cushions, which do a decent job at muffling gym clatter.

With a claimed 40 hours of battery life, the Crusher 540 Active holds its own in the full-size category, though this number seems average given the absence of ANC.

The companion app offers a “Personal Sound” test—one of the simplest yet effective hearing calibration tools around. You respond “yes” or “no” to tones, and it automatically adjusts the EQ to your hearing profile. It matched other hearing tests I’ve taken, so it seems legit.

You can switch between three preset equalizer modes: Music, Podcast (which boosts highs but cuts bass), and Movie (which lowers highs slightly). Unfortunately, there’s no option for custom EQ tweaking, so audiophiles must trust Skullcandy’s presets.

All in all, the app’s EQ modes are the only extra bells and whistles you get.

Feature rating: 3.5/5

Design: Gym-Ready or Just Trying?

• Lots of buttons on earcups
• Fit can be loose during certain exercises
• Removable, washable ear cushions

At first glance, the Crusher 540 Active look like typical full-size headphones, but the devil’s in the details. The earcups are loaded with controls: on the left, there’s a USB-C charging port, a 3.5mm jack, the signature bass slider, and a tiny power button. The right earcup hosts volume and playback controls, with tactile distinctions to help you operate them blindly.

The materials and design choices cater to gym users. The foam ear cushions are sweat-resistant and removable for easy cleaning—a feature I found genuinely effective, though reattaching them takes some patience.

The headband aims to minimize dirt buildup and maximize comfort, made with breathable materials and a lightweight frame that made workouts sweat-friendly. Skullcandy calls this “Clamp Force Secure Fit” technology, designed to keep headphones firmly on your head during exercise.

In practice, the fit was a mixed bag. The headphones slipped off during lying-down exercises, which was frustrating, though they stayed put well during standing workouts and runs.

A small but welcome touch: the earcups fold inward for easier transport—a feature I wish more brands adopted.

Color options are limited to black, white, or pink—far fewer than other Crusher models, which offer multiple colorways.

Design rating: 3.5/5

Sound Quality: Bass Lovers Rejoice

• 40 mm drivers per earcup
• Deep, powerful bass (especially with slider)
• Vocals lack some clarity and brightness

Let’s imagine the bass slider set to minimum for a moment. Even then, the bass remains prominent—after all, these are workout headphones from Skullcandy. The midrange picks up some benefit from this bass emphasis, but vocals occasionally lack the punch and brilliance found in other headphones emphasizing high frequencies.

You won’t get pristine audiophile-grade clarity or a detailed soundstage here. Some songs showed minor distortion, but that’s expected given the price and target use. For gym sessions and runs, the sound delivers just what you need: an energetic, bass-driven experience.

Skullcandy confirms that the 540 Active shares the same 40 mm drivers as the Crusher Evo. Given how well they fit the workout criteria, it makes sense that the 540 Active is essentially an Evo tweaked for gym users.

Sound quality rating: 3.5/5

Value for Money: Is It Worth It?

• You’re paying for unique bass-boosting features
• May not suit everyone’s workout needs

At $210, the Crusher 540 Active aren’t cheap, but they’re not premium flagship price either. The cost reflects the bass slider and some workout-focused tweaks, not just gym-ready features—after all, the Evo costs about the same, and the ANC Crusher ANC 2 is pricier.

If the bass slider sounds like your perfect gym companion, the price is justified. But if you think that novelty might wear off or you don’t expect to use it much, there are other full-size headphones that could suit your workouts for less.

Value rating: 3.5/5

Final Verdict: Should You Grab the Skullcandy Crusher 540 Active?

Alternatives to Consider

Jabra Elite 8 Active Gen 2

Jabra Elite 8 Gen 2 are pricier than Skullcandy and are earbuds, not over-ear headphones, but they sound great and offer top-tier noise cancellation. We include them here as our top earbuds for workouts.

Earfun Wave Pro

During testing, I took these older earbuds to the gym multiple times, and they performed wonderfully. They feature memory foam ear tips resistant to sweat damage, excellent battery life to avoid frequent charging, and surprisingly good sound for their price. Plus, they're quite affordable.

How I Tested the Skullcandy Crusher 540 Active

• Tested for at least three weeks
• Used at home, on runs, and in the gym

I paired the Crusher 540 Active with my Android phone throughout, using Spotify, Netflix, and other apps.

Most testing took place in my local gym and on neighborhood runs, as well as during home use, public transport rides, and walks.

This wasn’t my first time reviewing Skullcandy gear—I’ve tested earbuds, open-back, and over-ear headphones from the brand over six years. While I hadn’t tried the original Evo before, the 540 Active made a lasting impression.

“The bass slider lets your head literally shake to the beat of ridiculously boosted house or hip-hop tracks.”

— Enthusiastic reviewer

• What makes the Crusher 540 Active suitable for workouts?
  They have removable, sweat-resistant ear cushions, a bass slider to energize your music, and a design focused on gym use.
• Do these headphones offer active noise cancellation?
  No, they rely on passive noise isolation from the ear cushions.
• How long does the battery last?
  About 40 hours on a single charge, which is decent for full-size headphones without ANC.
• Can I customize the sound settings?
  Yes, via the app’s Personal Sound test and three preset EQ modes, but no full custom equalizer.
• Are these headphones good for all types of workouts?
  They excel for running and upright exercises but may slip off during floor-based workouts due to fit.

If you love the look and vibe of the Skullcandy Crusher 540 Active, why not bring that energy home? Shop your favorite album cover poster at our store to celebrate your music passion.