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Hi,
by trying to find a MWE that reproduce the mistake I finally found the reason why the header wrong. It was in one of the included sub-files where the textwidth was manually altered without resetting it afterwards.
Thanks for your help.

I tried your hint but still the same problem

Thank for your tip but that does not solve the problem..the header is still exceeding the text ( see attached pictures)

Hopefully this qualifies as an MWE...

\documentclass[a4paper,12pt,twoside,abstracton,bibliography=totoc]{scrreprt}

\usepackage[ngerman,english,american]{babel}
\usepackage[T1]{fontenc}
\usepackage[latin1]{inputenc}
\usepackage[ngerman, num]{isodate}

%Seitenlayout
%\usepackage{fancyhdr ...

sorry..totally forgot to attache that:

% ---------------------------------------------------------------------------------------------------------------------Vorspann
\documentclass[a4paper,12pt,twoside,abstracton,bibliography=totoc]{scrreprt}

\usepackage[ngerman,english,american]{babel ...

Hey,
sorry for my mistakes. I am new here and did not know how to do that...
As for the answer, the problem is not that the chapter name is too long but the header itself. No matter how short the chapter name is the header always exceed the text block by roughly 1 cm on the right.

Hey everybody,
a friend of mine is writing her PhD-thesis and has problems with the document's header: the header is longer than the text. It's always exceeding on the right side.
I tried various approaches without any solution...The used document class is "scrreprt", the text two sided. The first ...