I cracked my exhaust manifold on saturday.  Any suggestions on what headers or exhaust systems to go with.  1990 tracker with 1.6 8v.  I would like to get some more power out of it.

Thorley Headers are the only 50 state legal headers.

I had a calmini on mine worked great.

I went with the Calmini on my 89 and loved it.... 12 years after buying it, it was transplanted to one of Hutch's rides and I think still out there somewhere...  The last time I saw it, it was roaming the trails of Moab, UT... 
http://zukiworld.com/month_040108/feature_zigs-roaming-header.htm

A good quailty product...

Zig

Im gonna be the Devils Advocate here... How much HP gain can you expect with 4 cyl headers? Can it be noticed?

Normally headers compliment other upgrades IE: ignition, air intake, cam, head work, etc. Headers alone typically will make the engine breath easier but no noticed HP gain will be felt.

Stock exhaust and a good free flow muffler such as a flowmaster as a rule will out last and provide very similar results. That is not to say there aren't some very good and lasting headers on the market. But... they will not outlast the OEM manifold.

At least they never have on any of the high performance vehicle that I have owned.

                                                                             Tux... 

I went with a K&N filter, Thorley Header and a Dynomax turbo muffler I like the setup, my engine was abused so I could not notice much difference I do say to stay far away from the Pacesetter header though I had one and it broke early on after installing it.

I have to agree with tuxblacray ( how the hell do you say that anyway?) They may make more of a difference on the 8 valve engine, but the stock 16v exhaust manifold, other than being extraordinarily heavy and prone to cracking, is a pretty well designed exhaust manifold. The only reason I would change ( and I did ) is if yours is cracked, or you want to save a bunch of weight, and / or if you go the whole route as stated, header, airbox mod or K+N, 2" tubing all the way, free lowing cat or catless to a turbo style muffler. That and advance your timing a few degrees, run premium and you'll notice a substantial difference.

I have to agree with tuxblacray ( how the hell do you say that anyway?) They may make more of a difference on the 8 valve engine, but the stock 16v exhaust manifold, other than being extraordinarily heavy and prone to cracking, is a pretty well designed exhaust manifold. The only reason I would change ( and I did ) is if yours is cracked, or you want to save a bunch of weight, and / or if you go the whole route as stated, header, airbox mod or K+N, 2" tubing all the way, free lowing cat or catless to a turbo style muffler. That and advance your timing a few degrees, run premium and you'll notice a substantial difference.

LOL.... my friends just call me Tux...

They say a picture is worth a Thousand words so maybe this will help....

Tuxedo Black Stingray = TuxBlacRay

and yes it has headers with a few other interior / exterior engine tricks.....




There are countless ways to modify / tune smaller 6cy and 4 bangers. I had a Jeep Cj with a 258 6 cyl, Edelbrock 4 barrel manifold, Cam Dynamics Cam, Holley 650. and Hedman split manifold Headers. It would pull the wheels outta the hole in 1st gear.

The new HO 4 bangers have all kinds of tricks that can be done and so do these lil beasts. But, if your looking for power from headers alone it's not gonna happen. What most likely will happen is that you will buy some very nice ceramic coated headers and have to check the collector  religously for rust. That area is notorious for rusting and off roading is an extreme condition that will help to excellerate the rust process.

                                                                                                       Tux...  

That's why all Suzuki headers should be made of stainless steel, and have a turbo
attached 

Wild

That's why all Suzuki headers should be made of stainless steel, and have a turbo
attached 

Wild

Amen. Thanks be to IHI. The tutorial has ended, go in haste.