[Zman]

I have replace the fork seals in my sons 2004 DE300 once or twice a year and it only gets ridden 8 days a year. I have been using 46mm KYB fork seals and the tubes look pretty good with no significant wear, scratches or pits. I most recently replaced all of the bushings too. I seem to recall hearing the KYB seals are slightly 1mm shorter than the Ohlins seals but I have never seen the Ohlins seals as I got the bike with the red and black MSR or Moose seals in it.

We regularly depressurize the forks on the trailer and we use a cheap football between the wheel and fender to take some pressure off the forks while they are strapped down.

Is it possible the seals are leaking around the outside of the seal instead of past the fork tube sealing surface? I was thinking of trying a light coating of RTV on the outside of the seal next time in install them or maybe get some OE seals from Ohlins. I am sure they will only want my left ... elbow for a pair.