On an 02? How many times have the forks been taken apart and inspected? Your issue, braking bumps, sure sound like the beginning of the stroke. I had to ask about the sag, too much(under 100mm) and bye bye initial stroke of the forks. I would bet the farm Jeremy could fix that issue. I am pretty sure he has told me that most fork springs do not go under the service limit, BUT? Then there is the normal wear and tear, and how often the oil has been changed. Is the correct amount in now, and weight? And this has to be assuming you have the correct springs for your weight? The static sag confirms this. I can tell you that some older suspension gets pricey for worn out parts. I do not recall ever riding an 02 cr250, but if the adjusters can not dial it in, its either worn out, or bad to begin with. I would call him, cause I am no EXPERT either!