You know what i think the issue may be, simplest solution may be the answer. As you can see im using the same knuckle arms and going by what you say the wishbones are identical then it could be just the way the king pins have been screwed in. One question i never asked but are the hubs from the zx/zxr or zx-5 or zx-s? Now if from the zx-5 or s then the spacers (washers) need to be done correctly, personally i use the biggest washer from the castor block pack and skinny at the bottom of the knuckle arm and a skinny at the top as that stops the metal flange hitting the wishbone. i forgot about that so apologies for not mentioning it earlier.
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