new fork seals leaking

[Flounder]

I just finished putting in new fork seals, dust boots and progressive springs and after just a few miles both sides had drops of oil on the back sides of the dust boots. I filled the tubes with w15
oil to the recommended 5.5 inches down from the top, spring out, fully compressed which came out to be 15oz per side. does that see like a lot? I saw some where that volume was around 11.6 oz. The ride felt good I imagine if it was overfilled it would be pretty rigid. The OEM seals were installed with the chamfered edge down/ spring down and all bushings looked really good.
Any ideas before I do it all again?

[bs175dths]

I thought I had read, the factory springs used approx. 11 oz and the progressives used 5 or 6 oz., but I will need to research it. Also, how much air are you running in the forks?
The smallest of rust or dimples in the fork tubes, can scratch the seals and cause leaks.
I have a similar problem with some rear air shocks I bought from Ebay.
The seller didn't protect the dampers and one of them got damaged during shipping, causing it to leak.
I have since cleaned the light rust and raised areas caused by dimples, and am waiting for a new set of seals.

See if you can find the area on the seal which is leaking, then carefully inspect that side of the fork tube (in the area of fork travel) looking for what might damage the seal.
If none can be found, look through the area you used when you installed the seals. Damage may have been caused when the seals were slid down the fork tube.

Take your time when you are inspecting, small can do some damage.

Good Luck

-Ride On

[Flounder]

Thanks, tubes are super clean and smooth and I will check the oil level again.

[bs175dths]

My mistake..... the factory calls for a specific amount of oil while progressive calls for a measured level from the top of the tube, fork collapsed, and springs removed.
According to Tricky's post, your levels are correct.

Something else you might try is the insertion of a thin, flexible material between the tube and the seal.
The material needs to be uberly thin, but strong enough to not tear when used.

I had some leaking on my fork tubes and I used some mylar to clean the junk out from between the tubes and the seals.
It has been thousands of miles and I have been leak free. (and the fork tubes and lower legs are staying very clean)

Good Hunting!

[Roleketu]

Something else you might try is the insertion of a thin, flexible material between the tube and the seal.
The material needs to be uberly thin, but strong enough to not tear when used.

What you're talking about is the Sealmate. I have a couple but haven't needed to use them yet. For the price it's worth having them, $7.99 for two and $2.49 for shipping.