Excellent idea, and thank you for taking the time to step by step it. I actually thought of that but found out quickly what happened. I reinstalled the seat stopper backwards so it popped the circlip out of the grove and that fork spring was just floating around in the fork making the clicking noise. Note to self... don’t do forks late at night!I am wondering if you inadvertently replaced a fork guard screw with a brake rotor cover bolt (which is longer) and now the spring is stuck in the bottom of the fork tube
What I would do is remove the forks , and flip them and remove the rebound adjuster , pull up on the fork tube so the rebound rod is down a bit , then reinsert the rebound adjuster , now flip the fork and unscrew the fork cap , and (while holding the forks vertical) drop the outer tube down , and pull the cartridge straight out , and do not tilt it , lean it against the work bench as straight as possible to avoid oil from coming out the weep hole , now see if the spring is free , if its stuck and wont lift out , then that is the issue and the noise ......
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