K2 1000 Fork Seal keeps leaking

[Troutman]

I bought my 02 DL1000 last year, it's 10k miles so not much and in perfect condition, it has obviously been stored for 19 yrs indoors when not ridden , there is zero corrosion anywhere on the bike.
Early this year I noticed the right fork seal leaking slightly but was surprised as I had read in the service history they had been changed 2yrs ago (so less than 1k miles ago) ...
I booked the bike in to my garage I use (I usually do stuff like this but way too busy just now so pay someone else to do it) I told them they were newly replaced so look for any damage to the stanchions.
They fitted genuine Suzuki seals and said no damage, all good I thought then on Friday I was out for a ride around Cumbria and the same seal has started leaking again...so there must be some chrome damage/wear right? How did they not feel it?
What a pain because the labour cost is pretty high...any thoughts?

[Mr Nick]

Run something thin around between the seal & the stanchion just to make sure there's no dirt worked its way in - something like a piece of 35mm film.

[steveP Scooter]

If you have or can get hold of a digital micrometer (25 - 50mm) you will be able to measure the thickness of the stanchion at different points around the sliding area. You'll see any big differences that way

[Troutman]

yeah I'll try that, I have a set of digi callipers
No 35mm film though

[kwackboy]

A 3rd seal on the right stanchion in 10k miles  suggests there could be damage.

Lift the dust seal and run your fingers around the forks to feel for tiny imperfections, if you can't find anything my guess is the stanchion could be slightly bent. 

[UK_Vstrom650]

Depending on how recent they fixed it, take it back to the garage and get them to fix it properly.

[Troutman]

It was replaced 3 weeks ago but more importantly less than 300 miles ago.
Before that , 2 yrs ago so somethings not right.
I'll do that with the dust seal

[mr_diver]

It could also be play in the fork bushes...

Put the bike on the centre stand and pull and push both legs with the front wheel lifted.
You should be able to feel any free play.

Too much free play can knacker seals very quickly.

I'd also question the fitting technique.
Seals need to be placed on squarely and gently and not rammed over the top of the fork leg.
The smallest damage will cause a leak.
There could also be damage to the lip at the top of the stantion. No matter how careful you are damage there will in turn damage the seal.

The same goes for any rust or damage to the area above the normal area of travel.

[Troutman]

I agree Muff Diver
I don't think there is any play in the bushes and I had a look at the top of the stanchions last night for that reason and couldn't see anything , like I say the bike is like new, it hasn't been messed with.  No rust on them at all
I'll call the garage today, I did ask them to carefully check the stanchion as it was too soon since the original seal change for it to leak.

[oslin]

I had that on a 1300 Pan, I had replaced three lots seals, I could not find any damage to the staunching, In the end I replaced the staunching and all was fine after that but I never did find a good reason for the seal on one side leaking.

[steveP Scooter]

If a fork seal starts leaking again in short time after replacement it's normally one of two things; cheap seals or the chrome has worn on the travel area. I normally fit double lip seals and don't get problems with them unless the chrome is worn. It's always something I make a point of saying to my customers with leaky forks. I'll fit double lip seals, but if it starts to leak again in short time, look at replacing the stanchion because the chrome is probably worn.

[Troutman]

But would it have worn away after 10k miles?
The garage fitted Genuine Suzuki seals, this is after the 2nd set leaked so it's on it's 3rd set at £10k miles! The left fork is fine.
My garage said it might be the bushes worn but I'm not buying that, I think it must be the stanchion but it looks perfect.

[Mr Nick]

If it was out of true then yes, it could wear - it's not the best chrome out there. You're reaistically looking at taking it out & getting it properly assessed for straightness, roundness & wear then go from there.