Replaced FORK SEALS - still leaking?

My '90 project was a front end mess of fork oil goo. So, disassembled forks, installed fresh K&L seals, everything went together normally, buttoned it all up, bounced the forks a few times. Next morning, fork oil on the floor. Both seals are leaking at the tube/slider junction (seal location) without even being ridden. Now, before you suggest I got it back together upside down/backwards/sideways, I've done this before with no issues (other bikes).

Any ideas as to what could be causing the new seals to be leaking, even when stationary?

JOE in WI

 

Maybe fork oil is overfilled? I dunno just a guess.

 

My first thought, too. But I filled it to spec. (6" IIRC), compressed, without springs.

 

Front suspension:
Fork spring free length (L-M) 413.6mm (16.28 in.)
Fork spring free length (N-P) 427.1mm (16.81 in.)
Fork oil weight 5W (Honda SS-7)
Fork oil level (U.S. and Calif. L-M) 175mm (6.89 in.)
Fork oil level (Canada L-M) 187mm (7.36 in.)
Fork oil level (U.S., Calif. and Canada N-P) 178mm (7.01 in.)
Fork oil capacity (U.S. and Calif. L-M) 383cc
Fork oil capacity (Canada L-M) 394cc
Fork oil capacity (U.S., Calif. and Canada N-P) 386cc
Fork spring preload adjuster standard position (N-P) 3rd position from top
Steering bearing pre-load 1.0-1.5kg (2.2-3.3 lbs.)

Seems to be some variances?

 

Well, that muddies the waters, huh?
And, speaking of preload, these forks have some homemade preload spacers installed (thinwall steel pipe) of about 1.5 inches. Anyone know what the OEM spacer length is?

 

Did you check the forks for any burrs that may be causing damage to the new seals? Did you also replace the bushings or just the seals?? Also, how exactly do you seat the new seals?

Rollin

 

The fork tubes are excellent condition, not even scratched. The seals were carefully slid over the tubes with protective plastic wrap to preclude damage. Replaced just the seals, no bushings (they shouldn't affect the seal's ability to make a seal in any case, no?) To seat the seals, I worm-clamp a split PVC pipe to the tube and tap downward into place by sliding the fork tube downward. Always worked in the past.......

I suspect there may be more going on here, as the forks had obviously been apart before yet there was long-term leakage evident -- but clean fork oil in the forks. It's as though the previous seal replacement didn't work either.

 

MYSTERY SOLVED. My parts supplier gave me 43mm seals and the forks are 41mm. I can't believe I blindly put them on anyway (see avatar). Now I get to do the job twice.