are the seals installed correctly with embossed printing facing atmosphere? don't know you're procedure but i never install seals dry when rebuilding either cartridge or conventional forks. i very lightly coat the seal face with 3-in-1 oil then assemble, install, lock front brake, and work forks up and down several times. residual oil lightly coats the tubes for just one.....max of 2 wipe downs....that's it. more than that and you either installed incorrectly, faulty seals, nicked seals, nicked tubes, or incorrect fluid capacity over-fill.