Hello all, long-time lurker here with a '94 RVF400. Thanks for all the info so far - it's taken me from a poorly jetted bike with emulsion tubes upside down and intermittent spark to an incredible machine I'll never sell. I'm always amazed at the good will and information to be found in corners of the internet like this while the rest of it goes to hell. I've finally hit a snag I couldn't find with the search bar:

After a couple trans-oceanic moves, the shippers managed to blow out my fork seals. I had purchased a kit with bushings and seals ages ago, can't remember where they're from. But the new guide bushing is only 15mm tall while the old one I just pulled is 20mm. K-tech shows 15mm as the correct size, but there's no way to seat a 15mm bushing all the way into the fork by driving the bushing plus washer as the Haynes manual suggests - it would leave the bushing proud of its seat by 5mm as the washer sits on the next-higher ledge. It looks like the previous owner may have done just that judging by the wear marks on the tube. I'd rather not re-use the old bushing. Can I just fully seat the new one, leaving a 5mm gap to the washer, or do you think that will work itself free over time? K-tech lists this new 15mm size as correct for the bike. Cheers!

Have you a picture of the wear marks on the tube. The haynes manual pictures suggest that the bush should be 20mm long, 2 x seal thickness. Are the fork legs oem or a replacement copy ?

Thanks magg, I think you're right. You can see the wear mark if you click on the picture of the tube for the full size version. These are original forks as far as I can tell. I've just had a chat with a very helpful Rick Oliver and put in an order for the 20mm items. It seems K-Tech/NOK lists 15mm while Racetech suggests 20mm. I'll post a pic in a few days when the parts arrive to confirm and for anyone who runs across this later.

NC30 bushes are 15mm.

20mm seems to be the right fit for a '94 RVF - everything has gone together nicely. Thank you for the help, magg.