Do a search on here, this is a very common problem after installing heavier springs. The trick is when you screw the top cap into the leg, keep the cap stationary and twist the leg into the cap instead. I did this, and it works about 50% of the time. Just a few days ago I replaced the fork seals and I twisted one cap into the leg like normally, and there was no click, then I twisted the leg into the cap and there was a click. So far there hasn't been a problem. I rode with the click for about 6 months without a problem when I first installed the heavier springs (FRP .40's), it is just annoying.