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Ok, springs are the same length, spacer is the same length, same washers used at each applicable spot and the cap is at at the same spot on the damper rod, yet one fork is about 5mm shorter than the other. Nothing is obviously bent and the assembly works well. Preload and rebound are set the same on each.
What gives? Any ideas?
The forks have been disassembled, new bushings and new springs installed. The damper assembly was never removed from the inner tube. I don't know if they were equal before the rebuild (didn't notice), but I would like them to be equal now!!
 

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what points are you measuring from??:alcohol:
Cause at full extension, the forks are actually different lengths if you measure from the bottom of the axle holder to the top of the fork cap!
I belive the left fork(sitting on bike) is about 5 - 7 mm longer due to the axle design, it requires a larger boss as that is the large sholder side of the axle!!
 
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