I never had a single problem with plastic knights fitting on horses. The metal BSB model may require you to file down the barding on the right side of the back of the saddle a bit.
Make sure you are using matched leg sets(check the knee joints for the same symbol) and for most of mine I cut off the tab that holds the legs together to get a tighter fit.
Plastic knights should be a somewhat loose fit until they are glued in place, they aren't a tight fit like glade riders.
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