Hello... first timer...

 I have a '96 Sport that I want to make a bit better. 

As it stands now, about 155K miles, 1.8, 5 sp, auto hubs, std. running gear.  I am disappointed in a couple of things: first, power - anemic... passing is futile, highway speed is 60ish (5th gear |removethispart|@ 3500 rpm - too high for that speed?), 70 if I am pushing it, and 80 in a pinch - so that - second, the final drive ratios seem really low... to the point of compromising highway performance.

What I would like to do:  Power (obviously), improve highway performance, moderate body lift and somewhat larger tires - that is the basics.  Bumpers, winch, roof rack, lights - that sort of thing.  Not interested in body mods to the point of cutting and I'm not looking to create a boulder-crawling monster... just something a bit more "capable"?

I travel to the mountains (about 2 hours or so away) where I mostly stick to forest service roads and some other back roads that are not as well developed, but nothing crazy.  Perhaps some creek crossing and moderate hill climbing... maybe a dry creek bed?  (I got stuck last year in the fall traveling a backroad that was fairly muddy and rutted in places and had to hand-winch myself out.)

I have noticed that there doesn't seem to be a lot of after-market stuff for the Sport or the 1.8 (maybe I just don't know what to look for or where to look for it) and I thought I might be able to get some ideas and guidance from the forum.

So... thanks for being here for us "amateurs" and for sharing your passion and ideas.

Cheers!!

Perhaps a good place to start would be making sure that what you have is in "optimum" shape - when last was a "tune-up" done?  Wet & dry compression tests would be another good idea, you'll come away knowing the condition of the engine wear wise.

Historically, Suzuki engines have always been "high revving" - in that they are built to produce their power relatively high in the rpm range, and people who are not accustomed to this, do complain about the highway rpms as you are doing now - it's normal - but the lack of power is not.

The easiest way to achieve your performance goal will be to drop a J23 engine in (from an Aerio) - search the forums, you should find a few threads about it, but, something to bear in mind - all the mods you've listed - all except the first (improve highway performance) will actually detract from highway performance.

I don’t know about the Sport, but my 16 valve 1.6 will run 75 all day long in 5th gear. They are low geared, but also the engines power band is above 3k rpm.
As far as a lift, if it is available for the Sport, easiest would probably be a 2” spacer lift for the suspension. That would probably be easier than a body lift. My regular 4 door has a spacer lift and 235/75/15’s. You have 16” wheels, so you have a few more tire options. I would recommend staying with a 4 ply Pmetric tire. Down side is if you want an MT tire, they are primarily going to be 6 or 10 ply. The added weight of them will adversely effect your power on road and fuel economy.
It sounds like you maybe need to start with some maintenance and make sure that your 1.8 is running on top top form, and don’t be afraid of using the skinny pedal and letting that little motor sing, cuz high rpm is where the power lives.

hello again... Thanks for the input, gentlemen... I just rebuilt the alternator, rebuilt the power steering pump, and put in a new battery.  Previously, I had a government required insurance/registration inspection done by a local shop who found a leaking rear axel seal... long story short, never bothered to look up a schematic of the components so they would know what they were working with, did not know what they were doing, changed the dust seal (not the oil seal), wrecked parts in dis-assembly without first checking for new parts availability (and then had to have the part custom-made at a machine shop), and had to weld the part in place because the inside diameter was too large, , the axel continued to leak, and they would not stand behind their work.  I wound up re-doing the work myself and have had not had a problem since.  The Zuk is a blast to drive, very reliable, and pretty capable in stock form for what I do with it.  I will follow your suggestions - good advice to do anyway.  Thanks for your help, fellas!!   

I have a 1994 regular Sidekick 4door with the 1.6.  It really doesn't have much power but I love the little truck for what it is.  I still have fun driving it and like others have mentioned, you just have to rev it. I too started out offroading in stock form and found myself getting swallowed up by the ruts made by larger trucks.  I now have a 3" suspension lift from Zukination, 30" tires, winch, snorkel and rear locker.  These modifications have transformed this truck from zero to hero for the trails I do, which is similar to what you are describing.  With the sport I think you can probably run 245/75-16 with a 2-3" lift which is a 31" tire.  Don't quote me though because I don't have experience with the sport model. Add a winch bumper and winch and you should be golden.  As for the power the larger tires will only slow you down a little so really the only way to counter that would be the 2.3 engine swap.  The lack of power doesn't bother me too much, I just enjoy the truck for the advantages it has over larger trucks.  Its nimble on the trails and fits in tight squeezes where other trucks don't.  Obligatory show and tell pic:

I have a 97 Sport on 255/70 R16 tires, that measured 30.6" new. I do 70 mph at 3700 rpm. I have no acceleration issues on the hwy, unless on a long grade.  Foredom recommended checking the engine out. I would start there or just do the 2.3 swap. It's basically a bolt in swap.

Kreator builds an excellent lift kit, if you really want to mount 32 or 33s.  You can do 31s for much less.  OME Vitara springs and some spacers will get you there.

Today I checked the GPS speed against the OBDII rpm.  I was doing 72 mph at 3623 rpm.