[Neanderthal]

Just curious, have you done any of these:

1. Wheelies?
2. Compressed forks way down with tie-down straps at any time?
3. Hit a bad pot-hole or speed bump?
4. Run through a lot of sand or mud?

Not trying to accuse you of anything, those were just the first things that come to mind when talking about fork seals. Hope everything works out well for you!

Neanderthal

 

[Neanderthal]

Compressing the forks during transport normally does not cause an issue unless you compressed them all the way and for a long time. Even then, I've seen bikes go cross-country without issues, so that may not be the cause of your problem, but it's a starting point. There may be a totally different reason, including plain-old mis-assembly at the plant, which in your case might be the more likely scenario.

Neanderthal