New progressive front rebuild and my new seals are pouring fluid please advise

[New2Voyagers]

I just rebuilt the front fork 100% new bushings, new seals, new progressive, new Orings and brass washers. As soon as I hit the first bump I looked down to see fork oil everywhere. I'm wondering If I was given the wrong seals. When installing them the they kind of just "fell into" place. I thought it was weird how easily they went in with no force at all and essentially just the c clip holding them in place. Is this normal for the seals to fit this way or should they have to have some sort of "press" to them to seat properly. Thank you in advance! I also filled the tube in a compressed state to 145mm or 5.709 inches from the top as specified before inserting the springs. This took roughly between 8-12oz of fluid per fork. On a positive not the springs ride phenomenally now, just leak like a siv.

[Nails]

I looked down to see fork oil everywhere.

You don't actually come out and say that the seals leaked.

I thought it was weird how easily they went in with no force at all

Are the new ones the same size as the ones you took out?

You normally need to gently tap them in, taking care to keep them square. There are drivers, or use the old seal as a driver if it isn't too mangled.

took roughly between 8-12oz of fluid per fork.

The manual says 391ml, which works out to 13.75oz.

[New2Voyagers]

I looked down to see fork oil everywhere.

You don't actually come out and say that the seals leaked.

I thought it was weird how easily they went in with no force at all

Are the new ones the same size as the ones you took out?

You normally need to gently tap them in, taking care to keep them square. There are drivers, or use the old seal as a driver if it isn't too mangled.

took roughly between 8-12oz of fluid per fork.

The manual says 391ml, which works out to 13.75oz.

Yes the seals are leaking like there isn't even a seal there. They seemed the same size when I compared them, however the old ones remained in place even without the c clip in place, the new ones would slide in and out of place with just the movement of the inner fork, no tapping or pushing necessary. The manual measurement you refer of 391ml is that with the oem springs or the progressive swap out?

[Nails]

It's in the service manual. I recommend that you download it.

[New2Voyagers]

It's in the service manual. I recommend that you download it.

I appreciate the help, I have it downloaded as well as the supplemental manual, however in this particular instance it does me no good since the manual doesn't cover the progessive spring swap out, or the required amount of oil for the new setup. I printed out and followed the guide from the tech write up on the forum which specifies to fill the tube without the spring installed in a compressed state until the level reaches 145mm below the top of the inner fork tube.

[cushman eagle]

The new seals should take some force to install,not just a" fall in place" fit
When I replaced my seals I found piece of tubing that fit to drive the seal in,it did not take much force just a lite tap with a small hammer.

[New2Voyagers]

The new seals should take some force to install,not just a" fall in place" fit
When I replaced my seals I found piece of tubing that fit to drive the seal in,it did not take much force just a lite tap with a small hammer.

That's what I thought. So here's what I did so I could confirm I'm not losing my mind. I busted out the dusty old micrometer and measured the old seals. They measured 41mm Inside diameter 54mm outside diameter and 11mm thickness. The seals that's I was sent as part of the kit that was supposed to be specific for this bike measure 41mm ID 53mm OD and 8mm thick. I can only conclude I was sent the wrong seals. 1mm doesn't sound like a lot, but in terms of holding in fork oil that's a grand canyon. I have ordered another set of seals with the correct measurements and assured that it had the correct collar spring to seat properly. I will post an update if this resolves it.

[cushman eagle]

I am hoping you find that to be the fix.
In my GS850GL days,my forks started leaking so I got a set of 'money-saving' after-market seals,and installed them,and the first ride,they leaked
When I removed them I saw they had no garter spring but they were cheaper
Yes I got to do the job the 2nd time.

[Nails]

it does me no good since the manual doesn't cover the progessive spring swap out, or the required amount of oil for the new setup.

I don't think the brand of spring has much to do with the fork oil level; but lots of opinions about the best level, anyway. https://www.amervoyassoc.org/forum/view ... 338#p91338 describes some prevalent ones and the manual citations.

[VoyKimmer]

I suggest you purchase a Motion Pro fork seal driver and not use a pipe. I went thru so may seals and leaks until I brought the proper tools for the job, also watch Carl Leo’s video when he was at the Santa Fe rally and did a very good video on forks . I watch it every time I do my forks . Get the proper seals from a reputable company or get then from Carl. The proper amount of fluid for progressive s is 145 mm.
Also make sure you remove the filter and the spacer before putting the cap on. The cap sits right on top of the spring.

[Van Voyager]

Use an appropriate sized piece of ABS tubing, and putting the old seals upside down on top of the new seals, drive them home. Been doing it that way for 50 years. The only time I've ever had a leak was when I once used crappy 'Leak Proof' seals which were too small and leaked right away (just like the OP). I always use OEM seals, if available, and if not, I get a high quality industrial match from a hydraulic seal retailer.

[New2Voyagers]

The new seals should take some force to install,not just a" fall in place" fit
When I replaced my seals I found piece of tubing that fit to drive the seal in,it did not take much force just a lite tap with a small hammer.

That's what I thought. So here's what I did so I could confirm I'm not losing my mind. I busted out the dusty old micrometer and measured the old seals. They measured 41mm Inside diameter 54mm outside diameter and 11mm thickness. The seals that's I was sent as part of the kit that was supposed to be specific for this bike measure 41mm ID 53mm OD and 8mm thick. I can only conclude I was sent the wrong seals. 1mm doesn't sound like a lot, but in terms of holding in fork oil that's a grand canyon. I have ordered another set of seals with the correct measurements and assured that it had the correct collar spring to seat properly. I will post an update if this resolves it.

Just to finalize this post so that it helps anyone in the future, this issue was caused by incorrect sizing from an aftermarket supplier, and the seals aforementioned here are the sizes required for the rebuild. I suggest listening to all the knowledge these other riders had to offer it helped tremendously with the reinstall. I have rode 3000 miles leak free so far and this progressive upgrade was well worth the money! Thank you all!

[Van Voyager]

I have rode 3000 miles leak free so far ....

Impressive. I can only get about 60 miles in before I need to take a leak.

But seriously, good job on the seals.

[cushman eagle]

I have rode 3000 miles leak free so far ....

Impressive. I can only get about 60 miles in before I need to take a leak.

But seriously, good job on the seals.

That must be without coffee