I received an ILF setup today and when I attempted to assemble the limbs to the riser they wouldn't fit and I had a hell of a time getting them separated. Turns out there is one of two problems. Either the limb adjustment bolt is a smidge too fat or the U shaped notch at the base of the limb is a smidge too small. The limb was binding on the adjustment bolt. In addition the fit was so tight the limb wouldn't slide in far enuf for the springy pin to seat in the little divot.

I don't want to turn the bolt down a few thou so the alternative is to lightly sand the U shaped notch a little to allow it to fit on the bolt. Has anyone had this issue and what was your fix?

I've had similar problems.  We don't want to force expensive things to fit together.  However, we can't use them if they won't fit.  In the past, my solution has been to jam the new limbs onto the limb adjustment bolts until they fit using more force than I feel should be necessary.  After the first time, it gets easier.  YMMV, of course.

Can you remove the bushings from the limb bolt and sand them down a little bit. Put the bushings on a separate bolt run a nut up to the bushing and chuck in a drill or drill press and sand them until they fit

Thanks for the help. I lightly sanded the limb forks to remove some of the clearcoat and after some string wax on the forks I managed to get the issue resolved.