Step 1 is make it look like this.

The suspension part anyway

What is the best way to spend a few hundred bucks and get a little more power out of this thing?
Exhaust?
Intake?

Header will help, but the people doing it report the best "seat of the pants dyno" claim short ram intake, high flow cat & cat back exhaust are the best bang for the buck. You'll want 2" - 2 1/4". If you have a dremmel, spending a little time on port matching can't hurt, and won't cost you anything. You can play with moving the timing a couple degrees and see how that works out for you. Some people report bette accelleration by advancing the timing to 7*. I don't really notice much difference when I do it. And, get all the weight out of the vehicle you reasonably can.

"And, get all the weight out of the vehicle you reasonably can."

I guess my fat ass has to go on a diet then... lol

Thanks for the info.

What intake kits fit this?

What I mean is..... I've read that some are "going with the cheap Honda" kits.......?

Hey, I'm on a diet  But, a lot of people carry "junk" in their car. A couple hundred pounds of extra gear floating around in the back adds up. Ever notice you don't accelerate up hill as fast with a friend in the passenger seat? Same thing...

A lot of people make their own from their favorite local parts store (they often run sales on those things), or eBay. It's really a short-ram intake, not a CAI. What's on your rig now is a CAI, but the piping runs into the box, down the inside of the engine compartment, out through the firewall, and back up to the front of the vehicle (between firewall & fender) behind the turn signal. The intake at that point is SILLY narrow. Between that, and all the twists & turns... it's actually better to run the short ram in the warm engine compartment. I have a pic of what the intake looks like, I just have to find my darn camera....

You can do a snorkel too - which IS a CAI, and if facing forward is a ram intake. It's hard to keep it from looking ghetto if you DIY though, and the ARB one is like $300 I think  It looks SWEET though.

Thanks!  I actualy might snorkel it.  I'm prety handy with a hole saw and a dremel tool. 

I checked the factory piping and it is a joke.  Reminds me of trying to get a McDonalds milkshake through a stir straw.......

Any issues wit removing the cat?  I live in an area that does not require emissions testing

Not sure but If theres an o2 after the cat you might get a "low cat efficiency" code, which may turn on the engine light. Just a possibility.

Any issues wit removing the cat?  I live in an area that does not require emissions testing

It's super-bad for the environment to completely delete it, and doesn't give much improvement when compared to a cheap (sub $100) high-flow cat. Some people have reported that a lack of any backpressure causes a big loss in low-end torque... high flow cats seem to be where it's at.

Any issues wit removing the cat?  I live in an area that does not require emissions testing

You need the cats backpressure to run the egr right, or you'll be throwing p0400 code constantly. Ive heard good & bad about the high flow cats, seems 'most' can use em w/out issues though.

Fuzz

If you do not have to pass inspection your rig will run 100times better with the cat off. And about the egr just block it off too. All it will do is make your check engine light come on.

 X90's in San Diego.

Not sure how my 1.6L engine could be "superbad" for the enviornment in any configuration but I do hate having a check engine light.  I'm anal about things like that.

Don't punch holes in that nice X90. If money is tight, leave the motor alone 4 now & look into suspention. Calmini 3" is going to be best "bang for the buck"! Built more X90s than anyone I know "www.generationx90.com " and things like "snorkels" should be on the other end of your list. That is if you plan to off road with the rest of us. Body parts are rare for that X.

any one knows who makes the rear spare tire bumper combo? yes I did a search!

All tubes are custom. I designed all the bars, bumpers, rock sliders ect. & are one offs on all generatione x90 suzuki's. I will post a few picks later as they are on my lap top.