Other 2003 XR400R fork rebuild help

I recently acquired a 03 xr400r from an old rancher and the fork seals are bad among some other minor things. So I pulled the forks off and found out that one of my rebound Adjuster screws is broken. Is there any way I can take apart the forks without backing out that screw? also is there anywhere I can pick up some oem parts to fix the broken adjuster screw? I can only seem to find non adjustable caps.
 

SRAD97750

Moderator
Staff member
Howdy.
20 on the cap?
Or that bolt 15 is broken?
Or just the brass adjuster inside it?
xrfork.jpg


-BIG DAN:thumb:
 
Last edited:
2025-04-18 09.51.07.jpg2025-04-18 09.51.15.jpgI believe its the brass adjuster? I'm new to working on this stuff so I apologize if I get something incorrect. the pics will show my problem better than I can explain
 

SRAD97750

Moderator
Staff member
No problem!
Yes, you can take it apart without backing off the screws.
I just did xr400 forks in february.
-BIG DAN:thumb:
 
Oh that's good thank you. Would you happen to know where I might be able to acquire parts to fix it? Or will I just need to find some aftermarket caps?
 

SRAD97750

Moderator
Staff member
Oh that's good thank you. Would you happen to know where I might be able to acquire parts to fix it? Or will I just need to find some aftermarket caps?
I didn't see any fork bits on ebay, looks pretty scarce unless you're looking for a full set.
Aftermarket may be the way if they have the same adjuster system.
-BIG DAN:thumb:
 
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