I just rebuild a set using "James Gasket" seal kit. It has every seal in the forks but does not include the Guide Bushings. As stated in an above reply, the guide bushings keeps everything straight and happy. I think I paid $22 for a kit.

 

Did you have the lowers powder coated or chromed?
Maybe some powder over-spray or uneven chrome areas that are causing the leak.

 

Thanks for the advice. I replace the bushings this time around.

 

You can try removing it with some fine grit sandpaper but if that fails you'll need to replace the tube and at about $55 per rebuild kit it might be best to replace the tube and only spend money on one kit rather that 2 or 3.

 

Harley definitely has a problem with fork seals. Bought a new FXDL in 2008. Fork seals leaked from day one. Fixed under warranty. No more leaks. 2 years later bought a new FXDC. Forks seals again leaked from day one. Will be bringing it in to be fixed under warranty again. When will HD get it right?

 

That is why I bought a new front end from DEMONS cycle I know I know lots of people here hate DEMONS. But I for one love the things I got from them. My fork seals leaked and the fork tube had a bit of nickle showin tell me the tube was bad and since I wanted to go to chrome I just ordered a new front end and I think it looks good.