I have a 88 samurai with the stock 1.3L with weber carb and header. I run 33x13.5R15 super swampers with 6.5-1 transfer case gears and stock R&P gears with locker in the front and spool in the rear. I don't have enough power to run in 4 wheel Hi-range. In low range when i go through the mud i use 3rd gear but if i shift up to 4th it bogs down. But 3rd does not give me enough tire spin.  Would i be better of with more power or is there a R&P that could help with my gearing. The motor burns oil so i will either rebuild it or get a 1.6L 8V. I think if i had more power i could use my high range for the mud and keep my low range for climbing. If anyone could give me some input on this problem it would be greatly appreciated.

I have a 88 samurai with the stock 1.3L with weber carb and header. I run 33x13.5R15 super swampers with 6.5-1 transfer case gears and stock R&P gears with locker in the front and spool in the rear. I don't have enough power to run in 4 wheel Hi-range. In low range when i go through the mud i use 3rd gear but if i shift up to 4th it bogs down. But 3rd does not give me enough tire spin.  Would i be better of with more power or is there a R&P that could help with my gearing. The motor burns oil so i will either rebuild it or get a 1.6L 8V. I think if i had more power i could use my high range for the mud and keep my low range for climbing. If anyone could give me some input on this problem it would be greatly appreciated.

Couple things that may help... Don't be afraid to really spin that 1.3 6k+ is no problem, low range is fine to use with 4th and 5th too - unless you're running into the problem where reverse is too low because 6.5:1 is really deep - A lot of folks never use high range 4wd, like ever... :)It also sounds like your 1.3 is probably worn out... Upgrading to the 1.6 8-valve is awesome and you won't regret that...

Hope that helps.

-Eric

Everything Eric said. 

I run the 6.5 with 5.12 gears in my SJ-410 with 33x12.5 tires.  Works great, plenty of power, top speed of around 50 before I run out of rpm's with the 4 speed.  Anything other then a light grade and I'm down to third to climb the hill.  When I'm on the trails, if it's a nice smooth one, I might be able to use 1st gear.  But for the most part I run in 3rd and 4th in low range.  I also have the 970cc 4 cyl, so a bit less power then you have stock.

If I was building from scratch I would put in a 1.6L and, if I could afford it, a Shogun or Kicker 3 system so I could have two low ranges.  Then the lower transfer case if it was needed.

Everything Eric said. 

I run the 6.5 with 5.12 gears in my SJ-410 with 33x12.5 tires.  Works great, plenty of power, top speed of around 50 before I run out of rpm's with the 4 speed.  Anything other then a light grade and I'm down to third to climb the hill.  When I'm on the trails, if it's a nice smooth one, I might be able to use 1st gear.  But for the most part I run in 3rd and 4th in low range.  I also have the 970cc 4 cyl, so a bit less power then you have stock.

If I was building from scratch I would put in a 1.6L and, if I could afford it, a Shogun or Kicker 3 system so I could have two low ranges.  Then the lower transfer case if it was needed.

Third gear is what i use most in low range but if i try to shift up to 4th while i am in a mud pit it just does not have the power to spin the tires. I barely even use first or second gear i take off in third gear. I am hoping the 1.6L will help with the bogging down in 4th or maybe try a 4.9-1 transfer case gears and see if that gets me in the right gear range for the type of off roading i do. Is there much of a HP gain going to a 1.6L from the 1.3L. And how much of a gain could i get if i install the side draft harley carbs on the 1.6L.

There is a pretty good jump going to the larger engine, everyone I know who has done the swap has been very happy with it.

One thing you want to look at when looking at gears is what it will do to your overall ratios.  The jump from 3rd to 4th gear is one of the smallest jumps in your transmission.

1st gear - 3.652
2nd gear - 1.947
3rd gear - 1.423
4th gear - 1.000
5th gear - 0.864 or 0.795 (Post 88)

So you can only jump about 20% and hope that hits the sweet spot you are looking for.  The alternative of just getting 20-50% more power with an engine swap makes things a bit easier.

If you want to play around with your ratios without breaking out a calculator I recommend checking out a transmission calculator.  The one over at http://www.solemnwarning.net/transmission/ has most of the after market Suzuki SJ-413 transfer cases pre-programmed in.  So you just have to put in your rear end ratio.  It will show you the speed and rpm range for all 5 gears.