As I always have gone by the 'Save Early and Save Often' philosophy, I have had success with fixing the black screen.
The first time it happened to me, I already had two saves. I got the black screen, found out I could hit START and get the menu screen, so I made save 3. Quit and then loaded save 3... WALAA! Fixed... or so I thought. Proceeded to exit and then got the next loading screen. Unfortunately, I was in the hall with a broken droid and no ability to repair or do anything else relevant. So I then made save 4 with the droid and then quit and reloaded only to get the same broken droid.
I found this forum and proceeded to ftp my ini file and make the changes from anything with a D:\ to F:\Games\KOTOR2\
Uploaded the ini back, then booted KOTOR2 and reloaded from save 3, only to have the same thing happen. Next, I reloaded save 2, and had to redo a section of the board. Saved right before the droid's terminal stuff, and then before the final droid's terminal stuff (the point right before he gets hit). And it played through from there just fine.
What I get from this:
INI file changes fixed the black screen if a game is started new or restarted from a load before the droid gets shot.
There is NO need to clear the cache.
As the game states, Save often and in different slots!
SPECS: XBOX 1.0 / SmartXX / Custom Xecuter BIOS 4981
Hope this helps.