Just so happens, I've got a spare 04 CRF250X left fork.
I ruined my right fork and bought a pair for what it would have cost just for parts to fix the one.
I have had some suspensions come into my shop with the same problem, The screws that hold on the fork protector when tightened to tight dent the lower tube around the spring. Yoy need to take off the bottom part of the fork and get the spring out that way, It takes some time and you need to take the dents out of the tube
I would guess someone put your disk guard bolts where they shouldn't ie holding on the fork guards. it's a somewhat common issue,the guys over on tt's suspension forum were talking about it a little while ago.
yeah we got it out. one bolt in the the fork guard was much longer then the other 3 and was the issue. i lucked up and found a fork tube for $35 in town off the same year 450r so all is well now. gonna try to take it out for the first time this week sometime. thx guys
"Running is not a plan, Running is what you do when the plan fails"
The fork Guard bolts are the gold plated ones. The disk guard are standard silver color. The Disk guard bolts are longer and will compress the fork tube into the spring making it impossible to get out, if you use them to hold down the fork guards.