Ohlins fork manuals and service
Here are the related manuals for Ohlins forks for the RC51.
A guide to set sag.
It is in the box down the page. https://web.archive.org/web/20141126...Underrubrik_1/
Here is the graphic from that page.
General Ohlins tool manual
Check the service manuals to see what tools are needed for service. A variety of suspension shops will sell Ohlins tools. Kyle USA sells Ohlins tools and they have also made some tools for Ohlins forks in-house that are a less expensive option. I recommend speaking with Kyle USA about tools for the FG832 and FG322 RC51 Ohlins forks.
Advice on buying used forks
Never trust any Ohlins forks (or any forks for that matter) with "upgraded internals or valving" WITHOUT PROOF. A few unfortunate people I know have trusted the seller and ended up with nothing but stock parts upon tear-down. Forks have even been sold along a couple times this way before finding out the truth, so it may not intentionally be the sellers fault either. For proof, service pictures are a start, but not direct evidence. An invoice would be great (and one could phone to confirm it). Also the original parts pulled from the fork would be great.
If Ohlins FG832 or FG322 forks have a valving upgrade, confirm which superbike valve kit they have. As mentioned earlier, there are now two sets of superbike valve options: the older obsolete 3200-25, and the current 3200-27. The current 3200-27 kit is the most desirable upgrade. Again, look for PROOF. I am the only RC51 owner with the 3200-27 kit at this moment, but currently four other RC51 Ohlins fork owners have shown interest in upgrading their valving.
It's crazy IMO to spend a lot of money on upgraded suspension, but then not spring it for yourself. A mismatched spring notably impairs the performance of upgraded suspension, defeating the purpose of "upgraded suspension". Upgraded suspensions use linear springs which are better for overall suspension action, but they work for a notably narrower weight range than OEM progressive springs. People always talk about respringing a rear shock to match a rider's weight when buying used or new. The same thing applies to any Ohlins front suspension or forks. Ohlins forks should be sprung for a specific rider's weight. The previously installed Ohlins springs may work, but the owner needs to know what springs are in their forks to understand if the springs suit their weight. Any set of Ohlins forks for sale that doesn't have spring rate information explicitly stated or known should affect price imo.
When buying used, consider what servicing has been done, when it was done and the mileage on it. Front suspension should have maintenance. So recently serviced Ohlins forks and front suspension as well as lower mileage units should have a higher resale value, and justifiably so. Again, look for proof of the work.
Closely determine and consider all aspects of any forks for sale. Examine the condition, parts (complete or missing parts, refer to the installation guides linked which show all the parts related to the forks), upgrades (what they are and proof of them), servicing (proof), mileage, even boxing. For example, the Ohlins spacers are required and not cheap. Few pictures, undetailed pictures, and/or vague descriptions make is difficult to justify top end prices (communicate with the seller and try to get more information and pictures). Upgrades may include a few valving options, correct weight springs, additional springs, upgraded bolts, additional caliper brackets, etc. All of these aspects and considerations contribute to the price, so take all of them into account. Also, having an Ohlins shipping box is a significant advantage imo. Superior to ship for the fork purchase, and to use for any work or servicing on the forks at a later time. Over a long ownership, the box can be used multiple times.
There are similar prices on the used market for both Ohlins FG832 and FG322 RC51 forks. Ohlins FG832 and FG322 forks do not come up for sale very often and demand for both of them is high. In general, many people purchase whichever model they can find available. The one significant difference between FG832 and FG322 forks are the brake caliper mount designs (discussed earlier). On the used market, FG322 forks may currently sell for a few hundred $$ more than FG832 if they are otherwise identical (related considerations as mentioned earlier include valving upgrades, condition, servicing, completeness, mileage, other items provided, etc). In reality though, it is difficult to compare prices because invariably there are differences in all of the considerations. As such, sometimes FG832 forks may be worth significantly more money than FG322 forks, and vice versa. And comparative prices may change in the future with all the variables discussed earlier.
With high market demand and very low supply (which will further decrease over time) these used Ohlins forks made specifically for the RC51 go for high prices, with little to no depreciation through ownership at this time. The current used price for FG832 and FG322 forks range from $2000 to $2500+, depending on all the previously mentioned considerations. However, prices may change over time. So, as this thread gets older (it's current to 2014), do not consider that price range accurate. Instead, an easy and great way to get a reasonable current used price estimate is to search the various RC51 forums too see where used prices are at for Ohlins FG832 and FG322 forks, noting the related considerations. You may have to go back a few years or even more to get a decent sample size and estimate used prices.
Fork work for options in this guide
Much of the fork work for the options in this guide can be done by numerous shops (not the 30mm NIX upgrade though). However, considering the money a person will invest in these upgrades, I recommend using Kyle USA for the work. They are the Ohlins experts for the RC51
and have vast experience doing this work for the RC51. They also have very good pricing for the parts and labour. Visit their website for more information, or call them. Much of the information in this guide has come from Dan and Mike at Kyle USA and I thank them for their time. Without their knowledge, some of these options would not even be available for the RC51.
If you are in Canada and logistics to the US are too cumbersome, I found a shop and technician in Toronto to do suspension work, including this Ohlins fork work. The technician is ultra qualified with 30 yrs experience doing a lot of bike set-up, mechanic work, and suspension work, including on the Honda factory race team. People who want someone in Canada or that area of Canada to do top quality aftermarket suspension work can PM me for info.
Adapting other Ohlins fork applications to the RC51
It is not recommended to adapt Ohlins forks from another bike application to the RC51. Differences include fork length (in particular, the RC51 has a longer fork length than other bikes), clamping surface locations (Ohlins forks outer tubes flare in and out over their length with limited triple clamp mounting areas), axles, triples/stems (e.g., diameter, length), stroke, fender, fender mounts, etc, and they all combine to make things very difficult and problematic. It also results in a lot of work and if many compromises are made it will affect the bike geometry and handling. A few people have done it. Makis did a lot of work to adapt a set of different Ohlins forks to an SP1 and did a great job documenting it. The information is spread throughout his thread on many pages, so take your time to scroll through it all. https://www.rc51forums.com/forums/7-rc51-forums-bike-month/6033-vtr-1000r-sp1-rc-51-makis-edition.html
Hope this guide is helpful.
It's been a lot of work. Feel free to add input.