250 03 kx250 rebound dampener

My 03 kx250 rebound adjuster is slaughtered from the previous owner using a screw driver that was too small for the flat head slot in the screw. This is causing the adjuster screw to be very stiff when turning it, it feels like it is binding very badly. The other fork legs adjuster is smooth as butter, I'm not able to bottom out the affected adjuster so I can't tell if they are both at the same setting. Is there anyway I can pull this screw/adjuster fully out to clean the head up? All the diagrams in my manual show it as one piece and a new fork cap runs around $90 from factory Kawasaki. Any ideas?
 
My 03 kx250 rebound adjuster is slaughtered from the previous owner using a screw driver that was too small for the flat head slot in the screw. This is causing the adjuster screw to be very stiff when turning it, it feels like it is binding very badly. The other fork legs adjuster is smooth as butter, I'm not able to bottom out the affected adjuster so I can't tell if they are both at the same setting. Is there anyway I can pull this screw/adjuster fully out to clean the head up? All the diagrams in my manual show it as one piece and a new fork cap runs around $90 from factory Kawasaki. Any ideas?

I'd make sure the new cap was available, then pull the cap and see what you can do, chances are if the screw is fouled up you'll need to replace the cap, but maybe you'll get lucky and get it functional again and save you 90$
 
So theres no way to remove the clicker?

Probably but can you replace it without replacing the whole cap.....it looks from the parts schematic that that part is not serviceable by itself. its not going to hurt to try and de bugger the clicker as long as your prepared to replace the cap if it's determined the part is FUBAR.
 
So do you think part "11" hooks into the clicker screw?

I believe it contacts that screw, but you shouldn't need to worry about that, just pull the cap and see what you can do to get that clicker freed up, I'm afraid though that if you have trouble moving it freely now you may not be able to remove it without damaging the clicker screw beyond it being useful.
 
My 03 kx250 rebound adjuster is slaughtered from the previous owner using a screw driver that was too small for the flat head slot in the screw. This is causing the adjuster screw to be very stiff when turning it, it feels like it is binding very badly. The other fork legs adjuster is smooth as butter, I'm not able to bottom out the affected adjuster so I can't tell if they are both at the same setting. Is there anyway I can pull this screw/adjuster fully out to clean the head up? All the diagrams in my manual show it as one piece and a new fork cap runs around $90 from factory Kawasaki. Any ideas?

11 is damping rod. Bet them there are the same as a YZ 46mm. Bet you can find a cheep set of forks complete from flea-bay for cheeper than sending out, then you'll have all the spare parts you need and can revalve yourself having an extra set.

Actually Sparky....I like Gary's idea better than any other post, go with that route.
 
I'm just not sure flea bay is worth $180-$300 for used... I'll probably have to rebuild them mostly likely. Are you positive 03 yz250 forks well fit mine??
 
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