225 fork cap problem - this bugs me to no end!

[Huffa]

I got the circlip out easily and cleaned the whole area. There are no burrs. It pops in & out about a 1/2 inch but thats the fartherest it will come out as in picture. I can feel it catching on something but no idea what? I lubed it up & left set overnight, rotated the cap and still won't come out. Wonder what it's catching on?

The other fork had no problems, it popped right out. If I can't get out I can still change the oil as I have the bottom leg off but this perturbs me to no end that I can't get it out.

[DeePa]

Try getting it in as far as possible and spin it around in its groove.

otherwise, is it bent? did you check all parts of the groove for burs/junk? Not just the groove, but also the top and bottom of the grooves.

Not much help, but i hope you can get it. Youre the forkmaster.